Transfer Case and Extension Case Assembly

A: REMOVAL
1. Remove the manual transmission assembly from vehicle.
2. Remove back-up light switch and neutral position switch.





3. Remove transfer case with extension case assembly.
4. Remove shifter arm.





5. Remove extension case assembly.

B: INSTALLATION





1. Install center differential and transfer driven gear into transfer case.





2. Measure height "W" between transfer case and ball bearing on the transfer driven gear.

NOTE: Measure with bearing cone equipped.





3. Measure depth "X".

NOTE: Measure with bearing cone equipped.

4. Calculate space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 inch)





5. Select nearest washer in the provided table:
Standard clearance between thrust washer and taper roller bearing: 0.2 - 0.3 mm T (0.008 - 0.012 in T)

NOTE: T: Tight

6. Fit thrust washers on transfer drive shaft.





7. Measure depth "S" between transfer case and center differential.
ST 398643600 GAUGE





8. Measure depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE
9. Calculate space "U" using the following equation: U = S - T
10. Select suitable washer in the provided table:
Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)





Thrust Washer

11. Fit thrust washer on center differential.





12. Apply proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket: THREE BOND 1215B





13. Install extension assembly into transfer case.
Tightening torque: 37 Nm (3.8 kgf-m, 27.5 ft. lbs.)





14. Install shifter arm to transfer case.





15. Hang the shifter arm on the 3rd-4th fork rod.





16. Install transfer case with extension assembly to transmission case.
Tightening torque: 24.5 Nm (2.50 kgf-m, 18.1 ft. lbs.)

C: DISASSEMBLY
1. TRANSFER CASE
1. Remove reverse check assembly.





2. Remove oil guide.

2. EXTENSION CASE
1. Remove transfer drive gear assembly.





2. Remove shift bracket.
3. Remove oil seal from extension case.

D: ASSEMBLY
1. EXTENSION CASE
1. Using ST, install oil seal to extension case.

CAUTION: Use new oil seal.





2. Install shift bracket to extension case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
3. Install transfer drive gear to extension case.

2. TRANSFER CASE





1. Install oil guide to transfer case.
Tightening torque: 6.4 Nm (0.65 kgf-m, 4.7 ft. lbs.)
2. Install reverse check sleeve assembly to transfer case.