Transfer Case and Extension Case Assembly
Transfer Case And Extension Case AssemblyREMOVAL
Remove the manual transmission assembly from vehicle.
Remove the back-up light switch and neutral position switch.
Remove the transfer case with extension case assembly.
Remove the shifter arm.
Remove the extension case assembly.
INSTALLATION
Install the center differential and transfer driven gear into transfer case.
(A) Bearing outer race
(B) Extension case
Remove the bearing outer race from the extension case.
While pressing the bearing outer race horizontally, turn the driven shaft ten rotations.
Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
Measure the depth "X".
Note: Measure with bearing cone and thrust washer removed.
Calculate the space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 inch)
Select the nearest washer in the following table:
Standard clearance between thrust washer and taper roller bearing: 0.2 - 0.3 mm (0.008 - 0.012 inch)
Note: Be sure to keep the clearance within specifications.
Thrust Washer (50 X 61 X T) (Part 1):
Thrust Washer (50 X 61 X T) (Part 2):
Thrust washer (50 X 61 X t)
Fit the thrust washers on transfer drive shaft.
Install the bearing cone into extension case.
Measure the depth "S" between transfer case and center differential.
ST 32005073 GAUGE
Measure the depth "T" between extension case and transfer drive gear.
ST 32005073 GAUGE
Note: Thickness of ST: 15 mm (0.59 inch)
Calculate the space "U" using the following equation: U = 30 mm (1.18 inch) - S - T - 0.15 - 0.35 mm (0.0059 - 0.0138 inch)
Thrust Washer:
Select the suitable washer in the table.
Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)
Thrust washer
Fit the thrust washer on center differential.
Apply proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket: THREE BOND 1215 (Part No. 32005013) or equivalent
Install the extension assembly into transfer case.
Tightening torque: 40 Nm (4.1 kgf-m, 29.7 ft. lbs.)
Install the shifter arm to transfer case.
(A) Shifter arm
(B) 3rd-4th fork rod
Hang the shifter arm on 3rd-4th fork rod.
Install the transfer case with extension case assembly to transmission case.
Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.)
DISASSEMBLY TRANSFER CASE
Remove the reverse check assembly.
Remove the oil guide.
EXTENSION CASE
Remove the transfer drive gear assembly.
Remove the shift bracket.
Remove the oil seal from extension case.
ASSEMBLY
EXTENSION CASE
Using the ST, install the oil seal to extension case.
Note: Use a new oil seal.
Install the shift bracket to extension case.
Tightening torque: 24.5 Nm (2.5 kgf-m, 18.1 ft. lbs.)
Install the transfer drive gear to extension case.
TRANSFER CASE
Install the oil guide to transfer case.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
Install the reverse check sleeve assembly to transfer case.