Extension Case

Extension Case

REMOVAL

1) Remove the transmission assembly.
2) 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.

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





5) Install the transmission assembly.

DISASSEMBLY

1) Hit the extension case 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.

ASSEMBLY

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.





INSPECTION

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