Extension Case and Intermediate Case
Extension Case and Intermediate CaseREMOVAL
1. Remove the transmission assembly.
2. Remove the rear vehicle speed sensor.
3. Separate the extension case and intermediate case.
4. Separate the intermediate case and transmission main case.
INSTALLATION
1. Secure the intermediate case to transmission main case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.)
NOTE: Use a new gasket.
2. Attach the selected reduction driven gear shim to end surface of reduction driven gear with Vaseline.
3. Install the extension case to intermediate case.
NOTE: Use a new gasket.
Tightening torque: 25 Nm (2.5 kgf-cm, 18 ft. lbs.)
4. Install the rear vehicle speed sensor.
Tightening torque: 7 Nm (0.7 kgf-cm, 5.2 ft. lbs.)
5. Install the transmission assembly.
DISASSEMBLY
1. Take out the transfer clutch and multi-plate clutch hub assembly by lightly tapping the end of rear drive shaft.
NOTE: Be careful not to damage the oil seal of extension.
2. Remove snap ring using ST and press.
ST 18762AA000 COMPRESSOR SPECIAL TOOL
3. Supply compressed air to remove the clutch piston.
4. Remove the dust cover from extension case.
5. Remove the oil seal from extension case.
ASSEMBLY
1. Press-fit new oil seal using ST and press.
ST 498057300 INSTALLER
2. Press-fit the dust cover.
3. Insert the transfer clutch assembly, spring retainer, return spring and clutch spring retainer.
4. Using the ST and compressor, install the snap ring.
ST 18762AA000 COMPRESSOR SPECIAL TOOL
5. Install the transfer clutch.
NOTE: For 3-transfer clutch model, make sure the press plate is included.
6. Install the multi-plate hub assembly.
INSPECTION
^ Use compressed air to make sure the extension case routes are not clogged and not leaks.
^ Measure the extension end play and adjust it to within specifications.