Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Extension Case: Installation
- Clean the mating surface of the extension case and intermediate case.
- Select the thrust bearing. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Rear Drive Shaft>ADJUSTMENT .
- Select the shim for transfer reduction driven gear. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transfer Reduction Driven Gear>ADJUSTMENT .
- Install the selected thrust bearing to transfer clutch.NOTE: Install the thrust bearing in the correct direction.
- Attach the selected shim to transfer reduction driven gear.
- Apply liquid gasket to the extension case seamlessly, and temporarily install it.
Liquid gasket:
THREE BOND 1215B or equivalent
- Tighten the extension case mounting bolts and install the harness clips.
Tightening torque:
25 N.m (2.5 kgf-m, 18.4 ft-lb)
- Install the front wheel speed sensor. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Front Wheel Speed Sensor>INSTALLATION .
- Install the transmission body. Ref. to CONTINUOUSLY VARIABLE TRANSMISSION (TR690)>Transmission Assembly>INSTALLATION .
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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