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Extension Case

  1. Press in NEW oil seal in extension case. Install transfer pipe into extension case. Use caution not to damage seal rings and install transfer clutch assembly into extension case. Install parking pawl, shaft and return spring. Install inlet filter into transaxle case bore located behind transfer valve body.
  2. Ensure transfer seal lip is installed on transfer valve body and install transfer valve plate, transfer valve body and transfer duty solenoid. Tighten bolts to 62-80 INCH lbs. (7-9 N.m). Connect transfer duty solenoid connector. Install reduction drive gear assembly into rear of transaxle case until bearing shoulder makes contact.
  3. Using a plastic hammer, install reduction driven gear assembly into rear of transaxle case. Install NEW drive pinion lock nut and washer. Place transaxle manual plate in Park and tighten NEW drive pinion lock nut to 69-76 ft. lbs. (93-103 N.m). After tightening, stake lock nut securely.
  4. Determine extension case end play. Measure distance from extension case mating surface to end of rear drive shaft and subtract thickness of gauge block ("t"). This will be measurement ("L"). Refer to STEP 1 in illustration. See Figure .
  5. Measure distance from transaxle case mating surface to reduction drive gear end surface and subtract combined thickness of gauge blocks ("s") and ("t"). This will be measurement ("N"). Refer to STEP 2 in illustration. See Figure . Thickness of extension case gasket is .016" (.45 mm). This will be measurement ("G").
  6. Calculate clearance between reduction drive gear end surface and end of rear drive shaft. Use the following equation: Clearance + Thrust Needle Bearing = (L + G) - N  . Select appropriate thrust needle bearing to provide clearance of .002-.008" (.05-.20 mm). See SELECTIVE EXTENSION CASE THRUST NEEDLE BEARING  table.
  7. Install selected thrust needle bearing to end surface of reduction drive gear with petroleum jelly. Install NEW gasket and extension case to transaxle case. Tighten extension case-to-transaxle case bolts to 17-20 ft. lbs. (23-27 N.m). Install vehicle speed sensor No. 1 and tighten sensor retaining bolt to 53-71 INCH lbs. (6-8 N.m).
SELECTIVE EXTENSION CASE THRUST NEEDLE BEARING

Part No. Thickness - In. (mm)
806535020 .150 (3.80)
806535030 .157 (4.00)
806535040 .165 (4.20)
806535050 .173 (4.40)
806535060 .181 (4.60)
806535070 .189 (4.80)
806535090 .197 (5.00)
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