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 part.

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

NOTE: Install the thrust needle bearing in correct direction.

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





4. Tighten bolts to secure extension case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.)





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

DISASSEMBLY





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

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





2. Remove the transfer clutch pipe without deforming the pipe.
3. Remove the dust cover from extension case.
4. Remove the oil seal from extension case.

ASSEMBLY
1. Press-fit new oil seal using ST and press.
ST 498057300 INSTALLER
2. Press-fit the dust cover.





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





4. Install the transfer clutch assembly to the case.

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

INSPECTION
^ Spray compressed air, and make sure the transfer pipe and extension case routes are not clogged and have no leaks.
^ Measure the extension end play and adjust it to within specifications.