Case Extension and Gasket Replacement

Case Extension and Gasket Replacement

Special Tools

J 45012 Holding Fixture

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair)
2. Remove the exhaust system. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Vehicle Service) (Exhaust Muffler With Resonator, Exhaust, and Tail Pipe Replacement (Vehicle Service))
3. Remove the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement)
4. Support the transmission with a suitable jack.
5. Remove the transmission mount assembly. Refer to Transmission Mount Replacement (Service and Repair)




6. Install the propeller shaft flange holding fixture J 45012 .

Caution: Do not reuse the flange nut. Reusing the flange nut may cause damage to the transmission.

7. Remove and discard the propeller shaft flange nut.
8. Remove the propeller shaft flange. Refer to Propeller Shaft Transmission Flange Removal (6L50) ()Propeller Shaft Transmission Flange Removal (6L80) (Overhaul)




9. Remove the case extension housing bolts.
10. Remove the case extension housing.
11. Remove the case extension housing seal.

Installation Procedure




1. Install the case extension housing seal.
2. Install the case extension housing.
3. Install by hand the case extension housing bolts.





Caution: Refer to Fastener Caution (Fastener Caution).

4. Secure the case extension housing bolts in the specified sequence and tighten to 50 Nm (37 lb ft).




5. Install the prop shaft flange. Refer to Propeller Shaft Transmission Flange Removal (6L50) ()Propeller Shaft Transmission Flange Removal (6L80) (Overhaul)

Caution: Stake the flange nut onto the output shaft. Use the two staking grooves on the shaft to locate the staking points. Failure to stake the flange nut may result in damage to the transmission.

Note: Use a NEW propeller shaft flange nut.

6. Install the NEW propeller shaft flange nut and tighten to 105 Nm (77 lb ft).
7. Remove the propeller shaft flange holding fixture J 45012 .
8. Install the transmission mount assembly. Refer to Transmission Mount Replacement (Service and Repair)
9. Remove the transmission jack.
10. Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement (Two-Piece Propeller Shaft Replacement)
11. Install the exhaust system. Refer to Exhaust Muffler with Resonator, Exhaust, and Tail Pipe Replacement (Vehicle Service) (Exhaust Muffler With Resonator, Exhaust, and Tail Pipe Replacement (Vehicle Service))
12. Lower the vehicle.