Extension Housing Gasket

Extension Housing Gasket









Extension Housing Gasket

NOTE: Fixed flange transmission shown, slip yoke transmission similar.











Removal

All vehicles

1. With the vehicle in PARK, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

2. Remove the driveshaft. For additional information, refer to Driveshaft Removal and Replacement.

3. Remove the transmission insulator and retainer fasteners.

1. Remove the transmission insulator and retainer nuts.

2. Remove the transmission insulator and retainer bolts.





4. Using a suitable high-lift transmission jack, remove the transmission insulator and retainer.

1. Raise the transmission off the transmission insulator and retainer.

2. Remove the transmission insulator and retainer.





5. Disconnect the Output Shaft Speed (OSS) sensor connector.





Vehicles equipped with a fixed flange transmission

6. Remove the output shaft flange.

1. Remove and discard the output shaft flange bolt.

2. Remove the output shaft flange.





7. Using the Output Shaft Locknut Socket, remove and discard the output shaft retaining nut.





8. Remove the 9 extension housing-to-case bolts and the transmission extension housing.





Vehicles equipped with a slip yoke transmission

9. Remove the 9 extension housing-to-case bolts and the transmission extension housing.





All vehicles

10. Remove and discard the extension housing gasket.





Installation

All vehicles

1. NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.

Install the new extension housing gasket.





Vehicles equipped with a slip yoke transmission

2. Install the extension housing and the 9 transmission extension housing-to-case bolts.
- Tighten to 47 Nm (35 lb-ft).





Vehicles equipped with a fixed flange transmission

3. Install the extension housing and the 9 transmission extension housing-to-case bolts.
- Tighten to 47 Nm (35 lb-ft).





4. Inspect the new output shaft nut O-ring for cuts. If cut, install a new output shaft nut.





5. Using the Output Shaft Locknut Socket, install a new output shaft retaining nut.
- Tighten to 200 Nm (148 lb-ft).





6. Install the output shaft flange and a new output shaft flange bolt.
- Tighten to 130 Nm (96 lb-ft).





All vehicles

7. Connect the OSS sensor connector.





8. Install the transmission insulator and retainer.

1. Position the transmission insulator and retainer.

2. Lower the transmission onto the transmission insulator and retainer.





9. NOTE: It may be necessary to raise the back of the transmission slightly in order to install the bolts.

Loosely install the transmission insulator and retainer bolts.





10. Loosely install the transmission insulator and retainer nuts.





11. Tighten the transmission insulator and retainer bolts and nuts to 90 Nm (66 lb-ft).





12. Install the driveshaft. For additional information, refer to Driveshaft Removal and Replacement.

13. Start the engine. Move the selector lever through all the gear ranges, checking for engagements.

14. NOTICE: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure.

Using the scan tool with the engine running, check and make sure the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.