Extension Case
Extension CaseREMOVAL
1) Remove the manual transmission assembly from the vehicle.
2) Prepare the transmission for overhaul.
3) Remove the extension case.
4) Remove any remaining liquid gasket from the extension case and transmission case.
INSTALLATION
1) Select the thrust washer of the transfer driven gear, and attach to the extension case.
2) Apply a thin coat of oil to the outer surface of the bearing cone, and attach to the extension case.
3) Select the thrust washer of the transfer drive gear, and attach to the center differential.
4) Apply liquid gasket to the transmission case.
5) Install the extension case.
6) Install the manual transmission assembly to the vehicle.
DISASSEMBLY
1) Remove the transfer drive gear.
2) Remove the oil guide.
3) Remove the shift bracket.
4) Remove the bearing cone using the ST.
ST 18758AA000 PULLER
5) Remove the thrust washer and oil plate.
6) Remove the shifter arm oil seal.
7) Remove the reverse check system.
8) Remove the extension oil seal.
ASSEMBLY
1) Install the reverse check system.
2) Install the extension case oil seal.
3) Install a shifter arm oil seal using the ST.
ST1 18657AA000 INSTALLER
ST2 18671AA000 OIL SEAL GUIDE
4) Install the oil plate.
5) Select the thrust washer of the bearing, and attach to the extension case.
6) Apply a thin coat of oil to the outer surface of the bearing cone, and attach to the extension case.
7) Install the shift bracket.
8) Attach the oil guide and the transfer driven gear.
INSPECTION
1) Check to make sure there is no damage or cracks on the extension case. If damage or cracking is found, replace the extension case.
2) Inspect for oil leaks at the extension case and transmission case oil seals and mating surfaces. If there are oil leaks, replace the oil seal and liquid gasket.
ADJUSTMENT
TRANSFER DRIVEN GEAR BEARING THRUST WASHER ADJUSTMENT
1) Remove the bearing cone from the extension case using the ST.
ST 18758AA000 PULLER
2) Remove the thrust washer.
3) Measure depth "Z" between the extension case end area and bearing cone contact area.
ST 398643600 GAUGE
NOTE: When measuring depth "Z", subtract the thickness of the ST [15 mm (0.59 in)] from the measured value.
4) Remove the transfer driven gear.
5) Remove the center differential.
6) Remove the oil guides G and H.
7) Remove the snap ring and flat washer from the selector arm area.
8) Using an ST, remove the neutral set spring and support.
ST1 18756AA000 CLAW
ST2 399893600 PLIER
9) Lift the striking rod, and remove the spring pin.
10) Remove the selector arm No. 2 and the shifter arm.
11) Attach the bearing cone to the transfer driven gear.
12) Set the ST.
ST 18831AA000 GAUGE
13) Turn the transfer driven gear 10 or more times to seat the bearing properly.
14) Measure depth "Y" between the end of the ST and the bearing cone.
ST 18831AA000 GAUGE
15) Using the following calculation, calculate the transfer driven gear bearing thrust washer value "t". t = Z - (100 - Y) - {0.04 - 0.11 mm (0.0016 - 0.0043 in)}
16) Refer to the calculated value "t" to select the closest thrust washer from the following table.
17) Install the selector arm No. 2 and the shifter arm.
18) Install a new spring pin.
19) Using the ST, install the neutral set spring and support.
ST1 18756AA000 CLAW
ST2 399893600 PLIER
20) Install the flat washer and snap ring to the selector arm area.
21) Install the center differential.
TRANSFER DRIVE GEAR THRUST WASHER SELECTION
1) Measure height "Z" between the transmission case end area and ST.
ST 398643600 GAUGE
2) Measure depth "Y" between the end of the ST and the transfer drive gear.
ST 398643600 GAUGE
3) Using the following calculation, calculate the transfer drive gear thrust washer value "t". t = {Y - 15 mm (0.59 in)} - {Z - 15 mm (0.59 in)} -0.45 - 0.65 mm (0.018 - 0.026 in) t mm (in) Y mm (in) Z mm (in) 0.45 - 0.65 mm (0.018 - 0.026 in) 15 mm (0.591 in)
4) Refer to the calculated value "t" to select the closest thrust washer from the following table.
5) Install the selected thrust washer.