Connection Of Each Section

Install the parking pawl, shaft and return spring.

Fig 1: Installing Parking Pawl, Shaft & Return Spring
Install inlet filter to transmission case.

Fig 2: Installing Inlet Filter To Transmission Case
Install transfer valve plate, valve body and transfer duty solenoid to transmission case.
CAUTION:
- Be sure to install transfer seal lip to transfer control valve body.
- If transfer seal lip is damaged, replace seal with new one.
Tightening torque: 8+/-1 N.m (0.8+/-0.1 kg-m, 5.8+/-0.7 ft-lb)

Fig 3: Installing Transfer Valve Plate, Valve Body & Transfer Duty Solenoid
Connect connector to transfer duty solenoid.
Install the reduction drive gear assembly.
NOTE: Insert it fully into position until the bearing shoulder bottoms.

Fig 4: Installing Reduction Drive Gear Assembly
Using a plastic hammer, install reduction driven gear assembly, and tighten drive pinion lock nut.
NOTE:
- Be sure to use a new lock nut and a washer.
- Set the select lever in the "P" range.
- After tightening, stake the lock nut securely.
Tightening torque: 98+/-5 N.m (10.0+/-0.5 kg-m, 72.3+/-3.6 ft-lb)

Fig 5: Installing Reduction Driven Gear
Measurement and adjustment of extension end play.
1. Measure distance L from end of extension case and rear drive shaft with ST.
  ST 398643600 GAUGE
  
  L = Measured valve - 15 mm
  
  Fig 6: Measuring Rear Drive Shaft & Extension End Play
2. Measure the distance "L" from the transmission case mating surface to the reduction drive gear end surface with ST1 and ST2.
  l = Measured valve - 50 mm
  
  ST1 398643600 GAUGE
  
  ST2 499577000 GAUGE
  
  Fig 7: Measuring Distance "L" From Transmission Case Mating Surface To Reduction Drive Gear End Surface
3. Calculation equation:
NOTE: Add 0.05 mm (0.0020 in) and 0.20 mm (0.0079 in) thick shims to area "T". Calculate formula 2 to determine "H". The calculated "H" refers to the shim thickness range. Select shims of suitable thicknesses within the calculated "H" range.

T = (L + G) - l - H

T: Shim clearance

L: Distance from end of extension case to end of rear drive shaft

G: Gasket thickness (0.45 mm, 0.0177 in)

l: Height from end of transmission case to end of reduction drive gear

H: Thrust needle bearing thickness

0.05 - 0.25 mm (0.0020 - 0.0098 in)

Fig 8: Thrust Needle Bearing Chart
Installation of extension case and transmission case
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, see LOCATION AND INSTALLING DIRECTION OF THRUST NEEDLE BEARING .
2. Install the extension case to the transmission case.
  CAUTION: Be sure to use a new gasket.
3. Tighten bolts to secure the case.
Tightening torque: 25+/-2 N.m (2.5+/-0.2 kg-m, 18.1+/-1.4 ft-lb)

Fig 9: Installing Extension Case To Transmission Case
Install the vehicle speed sensor 1 (rear).
Tightening torque: 7+/-1 N.m (0.7+/-0.1 kg-m, 5.1+/-0.7 ft-lb

Fig 10: Installing Vehicle Speed Sensor 1 (Rear)