Extension Housing
Extension HousingSpecial Tool(s):
Disassembly
1. NOTE: To aid installation, index-mark the bolt hole position on the reverse idler shaft.
Remove the bolt and seal. Discard the seal.
2. Remove the reverse idler shaft support.
3. Remove the reverse idler gear.
4. Remove the reverse idler gear bearing.
5. Remove the reverse idler shaft.
6. NOTE: Inspect the countershaft front bearing for wear or damage before removing.
Using the special tools, remove and discard the countershaft front bearing.
7. NOTE: Inspect the bearing for wear or damage before removing.
Using the special tools, remove and discard the shift rail bearing.
8. Remove the reverse lamp switch and seal.
^ Discard the seal.
9. Remove and discard the output oil seal.
10. Inspect the magnet. Make sure it is securely attached in the extension housing.
Assembly
1. NOTE: A new extension housing will not have a magnet. A new magnet must be installed.
Apply adhesive to the magnet and install.
^ Only apply adhesive to the housing side of the magnet.
2. Using the special tools, install a new shift rail bearing.
^ Using a Heat Gun, heat the bearing area of the housing to ease installation.
3. Using the special tool, install a new countershaft bearing.
^ Using a Heat Gun, heat the bearing area of the housing to ease installation.
4. NOTE: Make sure the hole in the shaft aligns with the hole in the extension housing.
NOTE: The oil grooves on the gear, face the output side of the extension housing.
Install the reverse idler shaft, reverse idler gear bearings and reverse idler gear.
5. Install the reverse idler shaft support.
^ The ribs on the reverse idler shaft support face upward.
6. Install the idler shaft bolt with a new seal.
^ Tighten to 23 Nm (17 ft. lbs.).
7. Install the reverse lamp switch with a new seal.
^ Tighten to 20 Nm (15 ft. lbs.).
8. Install the new output oil seal after the bearing preload is completed during transmission assembly.