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 contact surface, and attach the selected thrust needle bearing to the end surface of the reduction drive gear.

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.





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

1. MP-T MODEL
1) Hit the edges of the rear drive shaft lightly with a plastic hammer, and take out the transfer clutch.

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





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.

2. VTD MODEL
1) Using ST1, ST2, ST3 and a press, remove the snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIER





2) Remove the test plug.





3) Send in compressed air, and remove the multi-plate clutch (LSD) piston.





4) Remove the multi-plate 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.

D: ASSEMBLY

1. 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.
^ Insert the transfer clutch assembly all the way to the bottom of the bearing shoulder.





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 multi-plate clutch (LSD) pipe to the extension case while being careful not to deform the pipe.





4) Apply ATF to a new O-ring and attach the test plug.





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





6) Using ST1, ST2 and ST3, attach the snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIER





INSPECTION
^ Blow with compressed air to make sure the transfer pipe and extension case routes are not clogged or leaking.
^ Inspect the extension end play, and adjust it to within the standard value.