Transfer Case and Extension Case Assembly
Transfer Case and Extension Case AssemblyREMOVAL
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) Install the bearing outer race to transfer driven gear.
4) While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
5) Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
6) Measure depth "X" of bearing insertion part of the extension case.
NOTE:
Measure with bearing outer race and thrust washer removed.
7) Calculate the thrust washer thickness "t" using the following calculation.
t = X - W + (0.15 - 0.20 mm (0.006 - 0.008 in))
8) Select the washer with the nearest value in the following table.
NOTE:
Be sure that it is always within the preload.
Preload of the taper roller bearing (amount of standard protrusion):
0.15 - 0.20 mm (0.006 - 0.008 in)
9) Install the thrust washer to extension case.
10) Replace the bearing outer race attached to the transfer driven gear with the extension case.
11) Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE
12) Measure the height "T" between the extension case and transfer drive gear.
ST 398643600 GAUGE
13) 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)
14) Select a suitable washer in the following table.
Standard clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in)
15) Install the selected thrust washer to center differential.
16) Apply a proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
17) Install the extension case assembly to the transfer case.
Tightening torque:
40 Nm (4.1 kgf-m, 29.5 ft-lb)
18) Install the gasket, and install the transfer case along with the extension case assembly to the transmission case.
NOTE:
Use a new gasket.
(1) Insert the axle shaft and hold, then move the ST (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.
19) Temporarily tighten the transfer case assembly.
20) Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin.
21) Operate the selector lever and shift lever COMPL to confirm the correct shifting into each gear is possible.
22) Tighten the transfer case assembly to the specified torque.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
23) Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin.
NOTE:
Use new spring pin.
24) 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.