Extension Case Disassembly and Reassembly
Extension Case Disassembly and ReassemblyDisassembly
1. Remove rear extension case from front extension case.
2. Disassemble rear extension case (2) as follows, if necessary.
a. Remove oil seal (3) from rear extension case using flat end rod or the like.
b. Remove needle bearing (1) using special tools.
3. Remove intermediate shaft from front extension case.
4. Remove oil seal from front extension case using flat end rod or the like, if necessary.
5. Remove intermediate front bearing and/or intermediate rear bearing using press (1) and bearing puller (2), if necessary.
Installation
1. Install intermediate front bearing (1) and/or intermediate rear bearing (2) using press (3) and bearing puller (4).
2. Install oil seal (1) to front extension case (2) until it become flush with case using special tool, and then apply grease to oil seal lip.
NOTE: When installing oil seal, face its spring side inward.
3. Install intermediate shaft with bearings to front extension case.
4. Assemble rear extension case (2) as follows.
a. Install needle bearing (1) to rear extension case until it become flush with case using special tool.
b. Install oil seal (1) to rear extension case (2) until it become flush with case using special tool, and then apply grease to oil seal lip.
5. Clean mating surfaces of front extension case and rear extension case (1), apply sealant to rear extension case as shown in figure by such amount that its section is 1.5 mm (0.059 inch) in diameter, mate rear extension case with front extension case, and then tighten bolts to specified torque.
A: Sealant 99000-31260SUZUKI Bond No.1217G
Tightening torque
Extension case bolt: 23 Nm (2.3 kg-m, 17.0 ft. lbs.)
