Transfer Case & Extension Case Assembly: Installation
Install the center differential and transfer driven gear into transfer case.
Remove the bearing outer race from the extension case.
- Bearing outer race
- Extension case
While pressing the bearing outer race horizontally, turn the driven shaft ten rotations.
Measure the height "W" between transfer case and taper roller bearing on the transfer driven gear.
Measure the depth "X".
Calculate the space "t" using the following equation: t = X - W + 0.2 to 0.3 mm (0.008 to 0.012 in)
Select the nearest washer in the following table:
Standard clearance between thrust washer and taper roller bearing:
0.2 - 0.3 mm (0.008 - 0.012 in)
| Thrust washer (50 x 61 x t) | |
|---|---|
| Part No. | Thickness mm (in) |
| 32008283 | 0.50 (0.0197) |
| 32008284 | 0.55 (0.0217) |
| 32008285 | 0.60 (0.0236) |
| 32008286 | 0.65 (0.0256) |
| 32008287 | 0.70 (0.0276) |
| 32008288 | 0.75 (0.0295) |
| 32008289 | 0.80 (0.0315) |
| 32008290 | 0.85 (0.0335) |
| 32008291 | 0.90 (0.0354) |
| 32008292 | 0.95 (0.0374) |
| 32008293 | 1.00 (0.0394) |
| 32008294 | 1.05 (0.0413) |
| 32008295 | 1.10 (0.0433) |
| 32008296 | 1.15 (0.0453) |
| 32008297 | 1.20 (0.0472) |
| 32008298 | 1.25 (0.0492) |
| 32008299 | 1.30 (0.0512) |
| 32008300 | 1.35 (0.0531) |
| 32008301 | 1.40 (0.0551) |
| 32008302 | 1.45 (0.0571) |
Fit the thrust washers on transfer drive shaft.
Install the bearing cone into extension case.
Measure the depth "S" between transfer case and center differential.
ST 32005073 GAUGE
Measure the depth "T" between extension case and transfer drive gear.
ST 32005073 GAUGE
Calculate the space "U" using the following equation: U = 30 mm (1.18 in) - S - T - 0.15 - 0.35 mm (0.0059 - 0.0138 in)
Select the suitable washer in the following table:
Standard clearance:
0.15 - 0.35 mm (0.0059 - 0.0138 in)
| Thrust washer | |
|---|---|
| Part No. | Thickness mm (in) |
| 32008270 | 0.9 (0.035) |
| 32008274 | 1.0 (0.039) |
| 32008271 | 1.1 (0.043) |
| 32008275 | 1.2 (0.047) |
| 32008272 | 1.3 (0.051) |
| 32008276 | 1.4 (0.055) |
| 32008273 | 1.5 (0.059) |
| 32008277 | 1.6 (0.063) |
| 32008278 | 1.7 (0.067) |
Fit the thrust washer on center differential.
Apply proper amount of liquid gasket to the transfer case mating surface.
Liquid gasket:
THREE BOND 1215 (Part No. 32005013) or equivalent
Install the extension assembly into transfer case.
Tightening torque:
40 Nm (4.1 kgf-m, 29.7 ft-lb)
Install the shifter arm to transfer case.
Hang the shifter arm on 3rd-4th fork rod.
- Shifter arm
- 3rd-4th fork rod
Install the transfer case with extension case assembly to transmission case.
Tightening torque:
24.5 Nm (2.5 kgf-m, 18.1 ft-lb)