Removal and Installation
Transfer Case and Extension Case AssemblyREMOVAL
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.
INSTALLATION
1. Install center differential and transfer driven gear into transfer case.
2. Remove bearing cone from the extension case assembly, and install to taper roller bearing of the transfer driven gear.
3. While pressing the bearing cone horizontally, turn the driven shaft ten rotations.
4. Measure height "W" between transfer case and taper roller bearing on the transfer driven gear.
5. Measure depth "X".
NOTE: Measure with bearing cone and thrust washer removed.
6. Calculate space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 inch)
7. Select nearest washer in the following table:
Standard clearance between thrust washer and taper roller bearing: 0.2 - 0.3 mm T (0.008 - 0.012 inch T)
NOTE: T: Tight
8. Fit thrust washers into extension case.
9. Install bearing cone into extension case.
10. Measure depth "S" between transfer case and center differential.
ST 398643600 GAUGE
11. Measure depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE
12. Calculate space "U" using the following equation: U = S + T -- 30 mm (1.8 inch) [Thickness of ST]
13. Select suitable washer in the table:
Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)
14. Fit thrust washer on center differential.
15. Apply proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket: THREE BOND 1215
16. Install extension assembly into transfer case.
Tightening torque: 40 Nm (4.1 kgf-cm, 29.7 ft. lbs.)
17. Install shifter arm to transfer case.
18. Hang the shifter arm on the 3rd-4th fork rod.
19. Install transfer case with extension case assembly to transmission case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18.1 ft. lbs.)