Extension Case

Extension Case

REMOVAL
1. Remove the transmission assembly.
2. Remove rear vehicle speed sensor.





^ MPT MODEL
3. Remove rear vehicle speed sensor connector.





^ VTD MODEL





4. Separate transmission case and extension case sections.

INSTALLATION
1. Attach the selected thrust needle bearing to the end surface of reduction drive gear with Vaseline.

NOTE: Install thrust needle bearing in the correct direction.

2. Install new gasket.
3. Install the extension case to the transmission case.





4. Tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18.1 ft. lbs.)
5. Install the rear vehicle speed sensor.
Tightening torque: 7 Nm (0.7 kgf-cm, 5.1 ft. lbs.)





^ MPT MODEL





^ VTD MODEL

6. Install the transmission assembly.

DISASSEMBLY

MPT MODEL





1. Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

NOTE: Be careful not to damage the oil seal in the extension.





2. Remove the transmission clutch pipe without bending pipe.

VTD MODEL





1. Remove snap ring using ST1, ST2, ST3 and a press.
ST1 398673600 COMPRESSOR
ST2 498627100 SHEAT
ST3 398663600 PLIERS





2. Remove test plug.





3. Remove clutch piston using compressed air.





4. Pay attention, not to bend pipe, and remove transfer clutch pipe.
5. Remove the dust cover from the extension case.
6. Remove the oil seal from the extension case.

ASSEMBLY

MPT MODEL
1. Using the ST and a press, press in a new oil seal.
ST 4980573001 INSTALLER
2. Press in the dust cover.





3. Install the transfer clutch pipe to extension case without bending pipe.





4. Install the transfer clutch assembly to the case.

NOTE:
^ Be careful not to damage the seal rings.
^ Insert the clutch assembly fully into position until the bearing shoulder bottoms.

VTD MODEL
1. Press new oil seal using ST and a press.
ST 498057300 INSTALLER
2. Press dust cover.





3. Install the transfer clutch pipe onto the extension case, taking care not to bend the pipe.





4. Install the test plug.
Tightening torque: 13 Nm (1.3 kgf-cm, 9.4 ft. lbs.)





5. Insert the multi-plate clutch, drive plates, driven plates, and spring retainer.





6. Install the snap ring using special tools 1, 2, and 3.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIERS

INSPECTION
^ Use forced air to make sure the transfer pipe and extension case routes are not clogged and do not leak.
^ Measure the extension end play and adjust it to within specifications.