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.
6) Remove the transfer driven gear and center differential as a unit.
INSTALLATION
1) Clean the mating surface of the extension case assembly and transfer case and the mating surface of transfer case and transmission cover.
2) Install the center differential and transfer driven gear into the transfer case.
3) Remove the bearing outer race from the extension case.
4) Install the bearing outer race to transfer driven gear.
5) While pressing the bearing outer race horizontally, rotate the driven shaft for ten turns.
6) Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
7) Measure depth "X" of bearing insertion part of the extension case.
NOTE:
Measure with bearing outer race and thrust washer removed.
8) Calculate the thrust washer thickness "t" using the following calculation.
t = X - W + (0.15 - 0.2 mm (0.006 - 0.008 in))
9) 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)
10) Install the selected thrust washer and bearing outer race to 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) - (0.15 - 0.35 mm (0.00590 - 0.0138 in))
S: Depth between transfer case and center differential
T: Depth between the extension case and transfer gear
30 mm (1.18 in): Thickness of ST
0.15 - 0.35 mm (0.0059 - 0.0138 in): Clearance
14) Select a suitable thrust washer in the following table.
Standard clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in)
15) Fit the thrust washer onto the center differential.
16) Apply liquid gasket seamlessly to the mating surface of transfer case.
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) Temporarily install the gasket to the transmission case side.
NOTE:
Use a new gasket.
19) Install the extension case assembly along with the transfer case to the transmission case.
(1) While moving the HANDLE to align the spline position, press in the transfer case assembly until the knock pin comes slightly out of transfer case.
ST 18631AA000 HANDLE
(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.
20) Temporarily tighten the transfer case assembly.
21) Install the shift lever COMPL to the shifter arm No. 2, then insert the remover or similar tool instead of spring pin.
22) Operate the selector arm and remover to confirm the correct shifting into each gear is possible.
23) Tighten the transfer case assembly to the specified torque.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)
24) Install the shift lever COMPL to the shifter arm No. 2, then fix it using a spring pin.
NOTE:
Use new spring pin.
25) Apply liquid gasket seamlessly to the mating surface of transmission cover.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
26) Install the transmission cover to transfer case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
DISASSEMBLY
TRANSFER CASE
1) Remove the interlock plate.
NOTE:
Do not remove the precoat bolt (B) if the parts are assembled as a transmission assembly. Do not reuse the precoat bolt and gasket once the interlock plate is 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.
3) Remove the dust cover.
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.
3) Install the dust cover.