Transfer Case and Extension Case Assembly: Installation

Install center differential and transfer driven gear into transfer case.

Fig 1: Installing Center Differential And Transfer Driven Gear Into Transfer Case
Measure height "W" between transfer case and ball bearing on the transfer driven gear.
NOTE: Measure with bearing cone equipped.

Fig 2: Measuring Height "W"
Measure depth "X".
NOTE: Measure with bearing cone equipped.

Fig 3: Measuring Depth "X"
Calculate space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
Select nearest washer in the following table:
Standard clearance between thrust washer and taper roller bearing:
1. 0.2 - 0.3 mm T (0.008 - 0.012 in T)
NOTE: T: Tight

Fig 4: Thrust Washer Identification Chart (50 x 61 x t)
Fit thrust washers on transfer drive shaft.
Measure depth "S" between transfer case and center differential.
ST 398643600 GAUGE

Fig 5: Measuring Depth "S"
Measure depth "T" between extension case and transfer drive gear.
ST 398643600 GAUGE

Fig 6: Measuring Depth "T"
Calculate space "U" using the following equation: U = S - T
Select suitable washer in the following table:
Standard clearance:
1. 0.15 - 0.35 mm (0.0059 - 0.0138 in)
  
  Fig 7: Thrust Washer Identification Chart
Fit thrust washer on center differential.
Apply proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket:
1. THREE BOND 1215B
  
  Fig 8: Applying Liquid Gasket
Install extension assembly into transfer case.
Tightening torque:
1. 37 N.m (3.8 kgf-m, 27.5 ft-lb)
  
  Fig 9: Installing Extension Assembly
Install shifter arm to transfer case.

Fig 10: Installing Shifter Arm
Hang the shifter arm on the 3rd-4th fork rod.

Fig 11: Hanging The Shifter Arm On The 3rd-4th Fork Rod
Install transfer case with extension assembly to transmission case.
Tightening torque:
1. 24.5 N.m (2.50 kgf-m, 18.1 ft-lb)
  
  Fig 12: Installing Transfer Case