Extension Case

Extension Case
REMOVAL
Remove the transmission assembly.
Remove rear vehicle speed sensor.

^ MPT MODEL





(A) Rear vehicle speed sensor

^ VTD MODEL





(A) Rear vehicle speed sensor

Separate transmission case and extension case sections.

INSTALLATION
Attach the selected thrust needle bearing to the end surface of reduction drive gear with Vaseline.

Note: Install thrust needle bearing in the correct direction.

Install new gasket.
Install the extension case to the transmission case.
Tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)





Install the rear vehicle speed sensor.
Tightening torque: 7 Nm (0.7 kgf-m, 5.1 ft. lbs.)

^ MPT MODEL





(A) Rear vehicle speed sensor

^ VTD MODEL





(A) Rear vehicle speed sensor

Install the transmission assembly.

DISASSEMBLY
MPT MODEL
Take out the transfer clutch by lightly tapping the end of the rear drive shaft.

Note: Be careful not to damage the oil seal in the extension.





(A) Transfer clutch
(B) Extension case
Remove the transmission clutch pipe without deforming pipe.





(A) Extension case
(B) Transfer clutch pipe

VTD MODEL
Remove snap ring using ST1, ST2, ST3 and a press.
ST1 32005075 COMPRESSOR
ST2 32005112 SEAT
ST3 32005074 PLIERS





Remove test plug.





(A) Test plug
(B) Extension case
Remove clutch piston using compressed air.





Pay attention, not to deform pipe, and remove transfer clutch pipe.





Remove the dust cover from the extension case.
Remove the oil seal from the extension case.

ASSEMBLY
MPT MODEL
Using the ST and a press, press in a new oil seal.
ST 32005087 INSTALLER
Press in the dust cover.
Install the transfer clutch pipe to extension case without deforming pipe.





(A) Extension case
(B) Transfer clutch pipe
Install the transfer clutch assembly to the case.

Note:
^ Be careful not to damage the seal rings.
^ Insert the clutch assembly fully into position until the bearing shoulder bottoms.





(A) Transfer clutch
(B) Extension case

VTD MODEL
Press new oil seal using ST and a press.
ST 32005087 INSTALLER
Press dust cover.
Install the transfer clutch pipe onto the extension case, taking care not to deform the pipe.





Apply ATF to new O-rings and install the test plug.
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)





(A) Test plug
(B) Extension case
Insert the multi-plate clutch, drive plates, driven plates, and spring retainer.





(A) Spring retainer
(B) Multi-plate clutch (LSD) piston assembly
Install the snap ring using special tools 1, 2, and 3.
ST1 32005075 COMPRESSOR
ST2 32005112 SEAT
ST3 32005074 PLIERS





INSPECTION
^ Use forced air to make sure the transfer pipe and extension case routes are not clogged and do not leak.
^ Measure the extension end play and adjust it to within specifications.
MPT model
VTD model