Transfer Case and Extension Case Assembly

Transfer Case and Extension Case Assembly

REMOVAL

1) Remove the manual transmission assembly from the vehicle.
2) Remove the back-up light switch and the neutral position switch.
3) Remove the transfer case together with the extension case assembly.
(1) Remove the transmission cover.





(2) Set and hold the selector lever COMPL to the 1st-2nd side, and remove the transfer case and extension case assembly as a unit.





4) Use the ST to push out the spring pin and remove the shift lever COMPL from shifter arm No. 2.
ST 398791700 SPRING PIN REMOVER 2





5) Remove the extension case assembly.





INSTALLATION

1) Install the center differential and transfer driven gear into the transfer case.





2) Remove the bearing outer race and thrust washer from the extension case.





3) While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
4) Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.





5) Measure depth "X" on bearing insertion part of the extension case.

NOTE:
Measure with bearing outer race and thrust washer removed.





6) Calculate the thrust washer thickness "t" using the following calculation.
t = X - W + (0.15 - 0.20 mm (0.006 - 0.008 in))
7) Select the washer with the nearest value in the following table.

Preload of the taper roller bearing (amount of standard protrusion):
0.15 - 0.20 mm (0.006 - 0.008 in)

NOTE:
Be sure that it is always within the preload.





8) Install the thrust washer to extension case.
9) Replace the bearing outer race attached to the transfer driven gear with the extension case.
10) Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE





11) Measure the height "T" between the extension case and transfer drive gear.
ST 398643600 GAUGE





12) Calculate the thrust washer thickness "U" using the following calculation.
U = S + T - 30 mm (1.18 in) [Thickness of ST]

NOTE:
Thickness of ST: 15 mm (0.59 in)

13) Select a suitable washer in the following table.

Standard clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in)





14) Fit the thrust washer onto the center differential.
15) Apply a proper amount of liquid gasket to the transfer case mating surface.

Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent





16) Install the extension case assembly to the transfer case.

Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)





17) Install the extension case assembly along with the transfer case to the transmission case.
(1) Insert the axle shaft and hold, then move the HANDLE to align the spline position to install.
ST 18631AA000 HANDLE
Part No. 38415AA100 AXLE SHAFT





NOTE:
Push the transfer case assembly until the knock pin protrudes slightly from the transfer case.





(2) Set and hold the selector lever to the 1st-2nd side, and install the transfer case assembly so that the shifter arm edge and fork rod does not contact.





18) Temporarily tighten the transfer case assembly.
19) Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin.





20) Operate the selector arm and remover to confirm the correct shifting into each gear is possible.
21) Tighten the transfer case assembly to the specified torque.

Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)





22) Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin.

NOTE:
Use new spring pin.





23) Install the transmission cover.

DISASSEMBLY

TRANSFER CASE

1) Remove the interlock plate.

NOTE:
Do not remove the interlock plate mounting bolt if the parts are assembled as a transmission assembly. Do not attempt to replace the interlock plate unless necessary. Do not reuse the bolts and gaskets once they are removed.





2) Remove the shift link assembly.

EXTENSION CASE

1) Remove the transfer drive gear assembly.
2) Remove the oil seal from the extension case.

ASSEMBLY

TRANSFER CASE

1) Install the shift link assembly to the transfer case.
2) Install the interlock plate to the transfer case.

NOTE:
^ Use a new bolt and gasket.
^ Before installing the interlock plate, clean the screw threads.

Tightening torque:
20 Nm (2.0 kgf-m, 14.8 ft-lb)





EXTENSION CASE

1) Using the ST, install the oil seal to the extension case.

NOTE:
Use a new oil seal.

2) Install the transfer drive gear to the extension case.