Extension Housing: Service and Repair

Extension Case

REMOVAL
1. Remove the transmission assembly.





non-turbo





Turbo Models

2. Remove rear vehicle speed sensor.





3. Separate transmission case and extension case sections.

INSTALLATION
1. Attach the selected thrust needle bearing to the end surface of reduction drive gear with Vaseline.

NOTE: Install thrust needle bearing in the correct direction.

2. Install new gasket.
3. Install the extension case to the transmission case.





non-turbo





Turbo Models

4. Tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)





5. Install the rear vehicle speed sensor.
Tightening torque: 7 Nm (0.7 kgf-m, 5.1 ft. lbs.)
6. Install the transmission assembly.

DISASSEMBLY
1. Take out the transfer clutch by lightly tapping the end of the rear drive shaft.





NOTE: Be careful not to damage the oil seal in the extension.





2. Remove the transmission clutch pipe without bending pipe.
3. Remove the dust cover from the extension case.
4. Remove the oil seal from the extension case.

ASSEMBLY
1. Using the ST and a press, press in a new oil seal.
ST 498057300 INSTALLER
2. Press in the dust cover.





3. Install the transfer clutch pipe to extension case without bending pipe.
4. Install the transfer clutch assembly to the case.





NOTE:
^ Be careful not to damage the seal rings.
^ Insert the clutch assembly fully into position until the bearing shoulder bottoms.

INSPECTION
^ Use forced air to make sure the transfer pipe and extension case routes are not clogged and do not leak.
^ Measure the extension end play and adjust it to within specifications.