Extension Case

Extension Case

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





3. Separate the transmission case and extension case section.





INSTALLATION
1. Apply Vaseline to the selected thrust needle bearing, and install to the reduction drive gear end surface.

NOTE: Install the thrust needle bearing in the correct direction.

2. Install a new gasket.
3. Install the extension case to transmission case.
4. Tighten bolts to secure the extension case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)





5. Install the rear vehicle speed sensor.
Tightening torque: 7 Nm (0.7 kgf-m, 5.1 ft. lbs.)





6. Install the transmission assembly.

DISASSEMBLY
1. MPT MODEL
1. Take out the transfer clutch assembly by lightly tapping the end of rear drive shaft with a plastic hammer.

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





2. Remove the transfer clutch pipe without bending the pipe.





3. Remove the dust cover from extension case.
4. Remove the oil seal from the extension case.

2. VTD MODEL
1. Extract the circlip with ST1, ST2 and ST3 and the press.

ST1 398673600 COMPRESSOR ST2 498627100 SEAT ST3 398663600 PLIERS:

2. Remove the test plug.





3. Remove the clutch piston using compressed air.





4. Remove the transfer clutch pipe without bending the pipe.





5. Remove the dust cover from extension case.
6. Remove the oil seal from the extension case.

ASSEMBLY
1. MPT MODEL
1. Press-fit the new oil seal using ST and the press.
ST 498057300 INSTALLER
2. Press-fit the dust cover.
3. Install the transfer clutch pipe to the extension case without bending the pipe.





4. Install the transfer clutch assembly to the case.

NOTE:
^ Be careful not to damage the seal ring.
^ Press-fit the transfer clutch assembly to bottom of bearing shoulder completely.





2. VTD MODEL
1. Press-fit the new oil seal using ST and the press.
ST 498057300 INSTALLER
2. Press-fit the dust cover.
3. Install the transfer clutch pipe to the extension case without bending the pipe.





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





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





6. Install the circlip using ST1, ST2 and ST3.

ST1 398673600 COMPRESSORST2 498627100 SEATST3 398663600 PLIERS:

INSPECTION
^ Use an air compressor to check that the transfer pipe and extension case routes are not clogged and are not leaking.
^ Inspect the extension end play, and adjust it to be within the standard value.