Intermediate Case
Intermediate CaseREMOVAL
1) Remove the transmission assembly from vehicle body.
2) Remove the extension case.
3) Remove the rear drive shaft.
4) Remove the transfer clutch assembly.
5) Remove the transfer reduction driven gear assembly.
6) Remove the intermediate case.
NOTE:
^ The total number of intermediate case mounting bolts is 14.
^ Inside the transmission is a single bolt (arrowed).
7) Remove the CVTF filter.
8) Remove the O-ring from the transmission case.
INSTALLATION
1) Clean the mating surface of intermediate case and transmission case.
2) Face the O-ring side of the CVTF filter to the intermediate case side, and install the CVTF filter.
NOTE:
Apply CVTF to the O-ring.
3) Install the O-ring to the transmission case.
NOTE:
^ Use new O-rings.
^ Apply CVTF to the O-ring.
4) Apply liquid gasket to intermediate case seamlessly.
Liquid gasket:
THREE BOND 1215 (Part No. 004403007) or equivalent
5) Install the intermediate case and the transmission hanger to the transmission case.
NOTE:
Make sure to install the arrowed bolt.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
6) Install the transfer reduction driven gear assembly.
7) Install the transfer clutch assembly.
8) Install the rear drive shaft.
9) Install the extension case.
10) Install the transmission to vehicle.
DISASSEMBLY
1) Remove the CVTF filler plug.
2) Remove all plugs from intermediate case.
3) Remove the reverse brake assembly.
ASSEMBLY
1) Install the reverse brake.
2) install all plugs to intermediate case.
Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)
NOTE:
Use new O-rings.
3) Install the CVTF filler plug.
NOTE:
Replace the gasket of CVTF filler plug with a new part after installing the transmission assembly to vehicle and adjusting CVTF fluid.
INSPECTION
^ Check the intermediate case for fissures, cracks or damage.
^ Check for leakage of CVTF from the connections between intermediate case and transmission case, and between intermediate case and extension case.