Extension Housing: Service and Repair

Extension Case

REMOVAL
1) Remove the transmission assembly.
2) Remove the rear wheel speed sensor.





^ MPT model





^ VTD model





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 petrolatum.

NOTE: Install thrust needle bearing in the correct direction.

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





4) Tighten bolts to secure the case.
Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)
5) Install the rear wheel speed sensor.
Tightening torque: 7 Nm (0.7 kgf-m, 5.1 ft. lbs.)





^ MPT model





^ VTD model

6) Install the transmission assembly.

DISASSEMBLY
MPT MODEL





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 it.
3) Remove the dust cover from the extension case.
4) Remove the oil seal from the extension case.

VTD MODEL





1) Using ST1, ST2, ST3 and a press`, remove snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 Seat
ST3 398663600 PLIERS





2) Remove the test plug.





3) Remove clutch piston using compressed air.





4) Remove the transmission clutch pipe without bending pipe.
5) Remove the dust cover from the extension case.
6) Remove the oil seal from the extension case.

ASSEMBLY
MPT MODEL
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.

VTD MODEL
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 test plug.
Tightening torque: 13 Nm (1.3 kgf-m, 9.4 ft. lbs.)





5) Insert multi-plate clutch, drive plate, driven plate and spring retainer.





6) Using ST1, ST2 and ST3, install snap ring.
ST1 398673600 COMPRESSOR
ST2 498627100 SEAT
ST3 398663600 PLIERS

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.