Transfer Case and Extension Case Assembly

Transfer Case and Extension Case Assembly

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.





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





2) Remove the bearing outer race from the extension case.





3) While pressing the bearing outer race 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 the thrust washer thickness 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 protrusion amount of taper roller bearing outer race:
0.2 - 0.3 mm (0.008 - 0.012 inch)

NOTE:
Be sure that it is within the standard protrusion amount.





8) Fit the thrust washers on transfer drive shaft.
9) Install the bearing cone into extension case.
10) Measure the depth "S" between transfer case and center differential.
ST 398643600 GAUGE





11) Measure the depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE





NOTE:
Thickness of ST: 15 mm (0.59 inch)

12) Calculate the space "U" using the following equation: U = S + T - 30 mm (1.18 inch) [Thickness of ST]
13) Select the suitable washer in the following table:





14) Fit the thrust washer on center differential.
15) Apply proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket:
THREE BOND 1215B (Part No. 004403007) or equivalent





16) Install the extension assembly into transfer case.





17) Install the shifter arm to transfer case.





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





19) Install the transfer case with extension case assembly to transmission case.





DISASSEMBLY

TRANSFER CASE
1) Remove the reverse check assembly.
2) Remove the oil guide.





EXTENSION CASE
1) Remove the transfer drive gear assembly.
2) Remove the shift bracket.





3) Remove the oil seal from extension case.

ASSEMBLY

EXTENSION CASE
1) Using the ST, install the oil seal to extension case.

NOTE:
Use a new oil seal.
2) Install the shift bracket to extension case.





3) Install the transfer drive gear to extension case.

TRANSFER CASE
1) Install the oil guide to transfer case.





2) Install the reverse check sleeve assembly to transfer case.