Manual Transmission/Transaxle: Service and Repair

The content of this article / image reflects manual update #18-143-09 dated 09/21/09.

Transfer Case and Extension Case Assembly

REMOVAL
1) Remove the manual transmission assembly from the vehicle.
2) Remove the back-up light switch & neutral position switch.
3) Remove the transfer case together with the extension case assembly.





4) Remove the shifter arm.
5) Remove the extension case assembly.





INSTALLATION
1) Install the center differential and transfer driven gear into the transfer case.





2) Remove the bearing outer race from the extension case.





3) While holding the bearing outer race horizontally, rotate the driven shaft for ten turns.
4) Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.





5) Measure depth "X" on bearing insertion part of the extension case.

NOTE: Measure with bearing outer race and thrust washer removed.





6) Calculate the thickness "t" of the thrust washer using following calculation. t = X - W + (0.2 - 0.3 mm (0.008 - 0.012 in))
7) Select the washer with the nearest value in the following table.
Preload of the taper roller bearing (amount of standard protrusion): 0.15 - 0.25 mm (0.006 - 0.010 in)

NOTE: Be sure that the amount of preload is within the standard value.





8) Fit the thrust washers on the transfer drive shaft.
9) Install the bearing outer race into the extension case.
10) Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE





11) Measure the height "T" between the extension case and transfer drive gear.
ST 398643600 GAUGE





NOTE: ST thickness [15 mm (0.59 in)]

12) Calculate the thickness "U" of the thrust washer using following calculation.
U = S + T - 30 mm (1.18 in) [Thickness of ST]
13) Select a suitable washer in the following table.





14) Fit the thrust washer onto the center differential.
15) Apply a proper amount of liquid gasket to the transfer case mating surface.





16) Install the extension assembly into the transfer case.





17) Attach the shifter arm to transfer case.





18) Hang the shifter arm on 3rd-4th fork rod.





19) Install the extension case assembly along with the transfer case to the transmission case.
Tightening torque: 24.5 N-m (2.5 kgf-m, 18.1 ft-lb)





DISASSEMBLY

TRANSFER CASE
1) Remove the reverse check assembly.
2) Remove the oil guide.





EXTENSION CASE
1) Remove the transfer drive gear assembly.
2) Remove the shift bracket.





3) Remove the oil seal from the extension case.

ASSEMBLY

EXTENSION CASE
1) Using the ST, install the oil seal to the extension case.

NOTE: Use a new oil seal.

2) Install the shift bracket to extension case.
Tightening torque: 24.5 N-m (2.5 kgf-m, 18.1 ft-lb)





3) Install the transfer drive gear to the extension case.

TRANSFER CASE
1) Install the oil guide to the transfer case.
Tightening torque: 6.4 N-m (0.65 kgf-m, 4.7 ft-lb)

NOTE: Use a new installing bolt.





2) Install the reverse check sleeve assembly to the transfer case.