Extension Case

Extension Case

REMOVAL
1) Remove the transmission assembly.
2) Remove the rear vehicle speed sensor.
^ MP-T MODEL





^ VTD MODEL





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 N-m (2.5 kgf-m, 18.4 ft-lb)





5) Install the rear vehicle speed sensor.
Tightening torque: 7 N-m (0.7 kgf-m, 5.1 ft-lb)
^ MP-T MODEL





^ VTD MODEL





6) Install the transmission assembly.

DISASSEMBLY

MP-T 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 while being careful not to deform the pipe.





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

VTD MODEL
1) Remove the snap ring using ST1, ST2, ST3 and a 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 while being careful not to deform the pipe.





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

ASSEMBLY

MP-T 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 while being careful not to deform 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.





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 while being careful not to deform the pipe.





4) Install the test plug.
Tightening torque: 13 N-m (1.3 kgf-m, 9.6 ft-lb)





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





6) Install the snap ring using ST1, ST2 and ST3.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 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.
MP-T MODEL

VTD MODEL