Page 777 of 2890
B3M0043A
4) Remove reverse check sleeve5.
Disassembly procedure is as follows:
(1) Using a standard screwdriver, remove snap ring
A
(Inner-28).
NOTE:
Replace snap ring with a new one if deformed or weak-
ened.
(2) Remove reverse check plate
B.
(3) Remove reverse check spring
Cwith camD.
(4) Remove reverse return spring
E.
(5) Remove reverse accent shaft
F.
(6) Remove O-ring
G.
NOTE:
Reverse check sleeve assembly uses an O-ring which
should not be scratched.
Be careful not to break adjustment shim placed between
reverse check sleeve assembly and case.
B3M0042A
5) Remove back-up light switch7.
6) Remove oil guide
9.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
21
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 778 of 2890
3. EXTENSION
G3M0526
1) Remove extension cover2and shift bracket1.
2) Remove snap ring
4(Outer-30).
3) Remove transfer drive gear
5.
CAUTION:
Do not remove ball bearing unless replacing.
4) Remove snap ring
6(Inner-72).
5) Remove ball bearing
7.
CAUTION:
Do not reuse ball bearing.
6) Remove oil seal
8.
CAUTION:
Do not reuse oil seal.
22
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 779 of 2890
C: ASSEMBLY
1. EXTENSION
G3M0953
Tightening torque: N⋅m (kg-m, ft-lb)
T: 25±2 (2.5±0.2, 18.1±1.4)
1) Installation of ball bearing1and selection of snap ring
2(Inner-72)
(1) Attach ball bearing
1(30 x 72 x 17) to extension
and install snap ring
2.
B3M0044A
(2) Measure clearance between snap ring2and outer
race of ball bearing
1with a thickness gauge.
CAUTION:
Replace ball bearing with a new one.
Clearance:
0—0.15 mm (0—0.0059 in)
(3) If the measurement is not within the specification,
select suitable snap ring
2.
Snap ring (Inner-72)
Part No. Thickness mm (in)
805172071 1.78 (0.0701)
805172072 1.90 (0.0748)
805172073 2.02 (0.0795)
23
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 780 of 2890
B3M0045A
2) Installation of transfer drive gear3
Press transfer drive gear into inner race of ball bearing.
B3M0046A
3) Selection of snap ring4(Outer-30)
(1) Install snap ring
4on transfer drive shaft.
(2) Measure clearance between snap ring and inner
race of ball bearing with a thickness gauge.
Clearance:
0—0.15 mm (0—0.0059 in)
(3) If the measurement is not within the specification,
select suitable snap ring.
Snap Ring (Outer-30)
Part No. Thickness mm (in)
805030041 1.53 (0.0602)
805030042 1.65 (0.0650)
805030043 1.77 (0.0697)
B3M0047A
4) Install extension cover6, gasket5and shift bracket7.
CAUTION:
Use new gasket.
5) Install oil seal
8with ST.
ST 498057300 INSTALLER
CAUTION:
Use new oil seal.
24
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 781 of 2890

B3M0043A
2. TRANSFER CASE
Assembly of transfer case is in the reverse order of disas-
sembly. Do the following:
1) Assembly of reverse check sleeve
(1) Install reverse accent shaft
F, check camD, return
spring
Eand check springConto reverse check
sleeve.
NOTE:
Be sure the bent section of reverse check spring is posi-
tioned in the groove in check cam.
(2) Hook the bent section of reverse check spring over
reverse check plate
B.
(3) Rotate cam so that the protrusion of reverse check
cam is at the opening in plate.
(4) With cam held in that position, install plate onto
reverse check sleeve and hold with snap ring
A(Inner-
28).
(5) Position O-ring
G(35.4 x 1.5) in groove in sleeve.
B3M0048A
CAUTION:
Make sure the cutout section of reverse accent shaft
is aligned with the opening in reverse check sleeve.
Spin cam by hand for smooth rotation.
If it does not return properly, replace reverse check
spring.
Move cam and shaft all the way toward plate and
release.
If cam does not return properly, replace reverse check
spring; if shaft does not, check for scratches on the
inner surface of sleeve. If sleeve is in good order,
replace spring.
Select a suitable reverse accent shaft and reverse
check plate by referring to “Neutral Position Adjust-
ment.”
25
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 782 of 2890

B3M0042A
2) Installation of shifter arm1and selector arm8
Install shifter arm into the partition from the front while
inserting selector arm into the opening in reverse check
sleeve. Pass shaft through hole in selector arm until its end
comes out of the rear of transfer case.
NOTE:
Apply a coat of gear oil to shifter arm. Also make sure oil
seal is positioned properly.
Tightening torque:
T1: 6.4±0.5 N⋅m (0.65±0.05 kg-m, 4.7±0.4 ft-lb)
T2: 10±1 N⋅m (1.0±0.1 kg-m, 7.2±0.7 ft-lb)
T3: 19.6±1.5 N⋅m (2.00±0.15 kg-m, 14.5±1.1 ft-lb)
T4: 25±2 N⋅m (2.5±0.2 kg-m, 18.1±1.4 ft-lb)
B3M0049A
3. COMBINATION OF TRANSFER CASE AND
EXTENSION ASSEMBLY
1) Install center differential
1and transfer driven gear2
into transfer case.
Tightening torque:
T: 37±3 N⋅m (3.8±0.3 kg-m, 27.5±2.2 ft-lb)
B3M0050A
2) Selection of thrust washer (52 x 61 x t)
(1) Measure height“W”between transfer case and ball
bearing on the transfer driven gear
3.
26
3-1SERVICE PROCEDURE
2. Transfer Case and Extension (AWD Model)
Page 783 of 2890