Transfer Case and Extension Case Assembly

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





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





5. Remove the extension case assembly.

B: INSTALLATION





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





2. Remove the 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 the height "W" between transfer case and taper roller bearing on the transfer driven gear.





5. Measure the 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 the nearest washer in the following table:
Standard clearance between thrust washer end taper roller bearing: 0.2 - 0.3 mm T (0.008 - 0.012 inch T)

NOTE: T: Tight

8. Fit the thrust washers on transfer drive shaft.





9. Measure the depth "S" between transfer case and center differential.
ST3 98643600 GAUGE





10. Measure the depth "T" between extension case and transfer drive gear.
ST3 98643600 GAUGE
11. Calculate the space "U" using the following equation: U = S - T





12. Select the suitable washer in the following table:
Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.013B inch)
13. Fit the thrust washer on center differential.
14. Install the bearing cone into extension case.





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





16. Install the extension assembly into the transfer case.
Tightening torque: 40 Nm (4.1 kgf-cm, 29.7 ft. lbs.)





17. Install the shifter arm to the transfer case.





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





19. Install the transfer case with extension case assembly to the transmission case.
Tightening torque: 25 Nm (2.5 kgf-cm, 18.1 ft. lbs.)

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





2. Remove the oil guide.

2. EXTENSION CASK
1. Remove the transfer drive gear assembly.





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

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

CAUTION: Use new oil seal.





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





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