Rear Extension Housing

DISASSEMBLY
1. Remove oil pump drive shaft.
2. Remove oil pump cover, as follows:
a. Using a torx socket wrench (T30), remove the three screws.





b. Install the two suitable bolts to the pump cover.
c. Remove the pump cover from the rear extension housing.
3. Remove drive rotor from driven rotor.
4. Remove driven rotor from rear extension housing.
5. Remove screw plug, spring, ball and valve seat, as follows:
a. Using a hexagon wrench, remove the screw plug.





b. Using a magnetic finger, remove the spring, ball and valve seat from the rear extension housing.
6. Remove center differential control coupling assembly, as follows:





a. Using a snap ring expander, remove the snap ring.
b. Remove the coupling assembly from the rear extension housing.





7. Remove separator and oil pump plate. Remove the three bolts, separator and oil pump plate.
8. Remove vehicle speed sensor drive gear, as follows:
a. Using a snap ring expander, remove the snap ring.
b. Remove the vehicle speed sensor drive gear.
9. Remove rear output shaft, as follows:
a. Using a snap ring expander, remove the snap ring.





b. Using SST 09325-12010 or equivalents, and a hammer, remove the rear output shaft.
c. Remove the two seal rings from the rear output shaft.
10. Remove dust deflector, as follows:
a. Using a screwdriver and hammer, remove the rear extension housing dust deflector.
b. Using a screwdriver and hammer, remove the rear output shaft dust deflector.





11. Remove oil seal. Using a screwdriver, pry out the oil seal from the rear extension housing.
12. Remove ball bearing, as follows:
a. Using a screwdriver, remove the snap ring.





b. Using SST 09316-60011 (09316-00011, 09316-00021) or equivalents, and a press, remove the ball bearing to the rear extension housing.

INSPECTION
1. Inspect driven rotor body clearance, as follows:
a. Install the drive rotor to the driven rotor.





b. Using a feeler gauge, measure the body clearance between the drive rotor and extension housing.
Standard clearance: 0.08-0.17 mm (0.0031-0.0067 inch)
Maximum clearance: 0.17 mm (0.0067 inch)
If the body clearance exceeds the maximum, replace the drive rotor or driven rotor.





2. Inspect driven rotor tip clearance. Using a feeler gauge, measure the tip clearance between the driver rotor and driven rotor.
Standard clearance: 0.05-0.15 mm (0.0020-0.0059 inch)
Maximum clearance: 0.15 mm (0.0059 inch)
If the tip clearance exceeds the maximum, replace the drive rotor or driven rotor.





3. Inspect oil pump side clearance. Using a steel straight edge and feeler gauge, measure the side clearance of oil pump.
Standard clearance: 0.03-0.10 mm (0.0012-0.0039 inch)
Maximum clearance: 0.10 mm (0.0039 inch)
If the side clearance exceeds the maximum, replace the drive rotor or driven rotor.

ASSEMBLY

NOTE: Coat all of the sliding and rotating surfaces with gear oil before assembly.

1. Install ball bearing, as follows:





a. Using Special Service Tool (SST) 09316-60011 (09316-00011, 09316-00031) or equivalents, and a press, install the ball bearing.





b. Select a snap ring that will allow minimum axial play.





c. Using a screwdriver, install a new snap ring.
2. Install dust deflector, as follows:





a. Using SST 09316-60011 (09316-00011, 09316-00041) or equivalent, and a hammer, install a new rear extension housing dust deflector.





b. Using SST 09316-20011, 09316-60011 (09316-00011) or equivalents, and a press, install a new rear output shaft dust deflector.





3. Install oil seal. Using SST 09316-60011 (09316-00011, 09316-00031) or equivalents, and a hammer, drive in a new oil seal.
4. Install rear output shaft, as follows:





a. Using SST 09316-20011, 09316-60011 (09316-00011, 09316-00031) or equivalents, and a press, install the rear output shaft.
b. Install the two seal rings to the rear output shaft.





c. Select a snap ring that will allow minimum axial play.





d. Using a snap ring expander, install a new snap ring.
5. Install vehicle speed sensor drive gear, as follows:
a. Install the vehicle speed sensor drive gear.
b. Using a snap ring expander, install the snap ring.
6. Install oil pump plate and separator, as follows:
a. Install the oil pump plate.
b. Install the separator.





c. Install and torque the three bolts.
Torque: 4.9 Nm (43 inch lbs.).
7. Install center differential control coupling assembly, as follows:
a. Install the coupling assembly to the output shaft.





b. Using a snap ring expander, install the snap ring.
8. Install valve seat, ball, spring and screw plug, as follows:
a. Apply gear oil to the ball.





b. Install the valve seat, ball and spring.
c. Apply liquid sealer to the screw plug.
Sealant: THREE BOND 1344, LOCTITE 242 or equivalent.
d. Using a hexagon wrench, install and torque the screw plug.
Torque: 29 Nm (22 ft. lbs.).
9. Install driven rotor, as follows:
a. Apply gear oil to the driven rotor.
b. Install the driven rotor.
10. Install drive rotor, as follows:
a. Apply gear oil to the drive rotor.





b. Install the drive rotor.

NOTE: Align the alignment marks.

11. Install oil pump cover, as follows:
a. Install the oil pump cover.
b. Using a torx socket wrench (T30), install and torque the three screws.
Torque: 4.9 Nm (43 inch lbs.).





NOTICE: Align the oil hole of the rear extension housing and oil groove end of the oil pump cover.

12. Install oil pump drive shaft.