Extension/Adapter Housing

Fig. 108:

1. Install the extension housing bushing with Installer 8156 and Handle C-4171, if necessary. Be sure that the oil feed hole is at the 12 o'clock position when installed.

Fig. 109:

2. On 4X2 vehicles, install the extension housing seal with Installer 8154 and Handle C-4171, with the weep hole at the bottom.
3. On 4X4 vehicles, install the adapter housing seal with Installer C-3860-A and Handle C-4171.
4. Use Installer 8239 and Handle C-4171 to install the crossover cam bushing into the extension/ adapter housing.
5. Clean the rear of the transmission case of all sealer.
6. Install the reverse countershaft gear bearing race onto the reverse countershaft gear bearing.

Fig. 110:

7. Using the Gauge Bar 6311, measure the distance from the back of the bearing race to the gauge bar.
8. Measure the thickness of the gauge bar. Record the total of the two measurements.
9. Clean all the sealer from the extension/adapter housing.

Fig. 111:

10. Using Gauge Bar 6311 across the housing face, measure the distance to the bottom of the reverse countershaft bearing race bore.
11. Subtract the thickness of the gauge bar from the measurement and record the result.
12. The difference between the two measurements is the endplay for the reverse countershaft gear assembly.
13. Install the required shims to achieve the correct end-play for the reverse countershaft gear assembly into the reverse countershaft bearing race bore. The correct end-play is 0.15 - 0.25 mm (0.006 - 0.010 inch).
14. Use Installer to install the reverse countershaft bearing race into the extension/adapter housing.
15. Install the back-up lamp switch and a new gasket into the extension/adapter housing. Torque the switch to 28 Nm (20 ft. lbs.).
16. Install the crossover cam into the extension/ adapter housing.

Fig. 112:

17. Install the bolt to hold the crossover cam to the extension/adapter housing.
18. Install the crossover detent plunger into the extension/adapter housing
19. Install the crossover detent spring into the extension/adapter housing.

Fig. 113:

20. Install the crossover detent plug into the extension/adapter housing. Torque the plug to 47.5 Nm (35 ft. lbs.).
21. Apply sealer to the surface of the transmission case.
22. Install the extension/adapter housing onto the transmission case.
23. Install the bolts to hold the extension/adapter housing onto the transmission gear case. Torque the bolts to 48 Nm (35 ft. lbs.).