Extension Housing: Service and Repair
Extension Case Leak Elimination1. Remove the transfer case.
2. Using a suitable tool release the four bolts from inside the vehicle holding the transfer gear selector housing and adaptor bracket.
3. From underneath the vehicle using a suitable tool release the nine bolts holding the extension housing.
4. Remove the extension housing and discard the gasket.
5. Place extension housing on the bench and remove the oil seal.
6. Ensure that all the surfaces are clean and the case is free from damage. If damage has been found on the case, replace the case.
7. If the case has to be replaced, fit the two dowels to the case.
8. Fit a new gasket and oil seal using the rear oil seal replacer LST108.
9. Fit the extension case onto the transmission ensuring the oil seal is not damaged by the extension shaft.
10. Fit and tighten the nine bolts to 23 Nm (17 ft lbs).
11. From inside the vehicle refit the four bolts which hold the transfer gear selector housing and adaptor bracket.
12. Secure the four bolts to 77-90 Nm (55-65 ft lbs).
13. Refit the transfer case.