Extension Case

Extension Case

REMOVAL

1) Remove the transmission assembly.
2) Disconnect the rear vehicle speed sensor connector.





3) Remove the rear vehicle speed sensor.





4) Remove the extension case.





INSTALLATION

1) Attach the selected reduction driven gear shim to end surface of reduction driven gear with vaseline.
2) Install the extension case.

NOTE:
Use a new gasket.

Tightening torque:
25 N-m (2.5 kgf-m, 18.4 ft-lb)





3) Install the rear vehicle speed sensor.

Tightening torque:
7 N-m (0.7 kgf-m, 5.2 ft-lb)





4) Connect the rear vehicle speed sensor connector.





5) Install the transmission assembly.

DISASSEMBLY

1) Take out the transfer clutch and multi-plate clutch hub assembly by lightly tapping the end of rear drive shaft.

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

2) Remove the snap ring using the ST and press.

ST 18762AA000 COMPRESSOR SPECIAL TOOL





3) Supply compressed air to remove the clutch piston.





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

ASSEMBLY

1) Press-fit the new oil seal using ST and the press.

ST 498057300 INSTALLER

2) Press-fit the dust cover.
3) Insert the transfer clutch assembly, spring retainer, return spring and clutch spring retainer.





4) Using the ST and compressor, install the snap ring.

ST 18762AA000 COMPRESSOR SPECIAL TOOL





5) Install the transfer clutch.
6) Install the multiplate hub assembly.

INSPECTION

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