Extension Housing: Service and Repair

MANUAL TRANSMISSION EXTENSION HOUSING REMOVAL / INSTALLATION

Removal

1 With the vehicle in neutral, position it on a hoist. See Lifting.
2 Remove the drain plug and drain the transmission fluid.
3
NOTE:To maintain initial propeller shaft balance, mark the propeller shaft centering socket yoke and rear axle universal joint flange so they may be installed in their original positions.
Remove and support the rear propeller shaft.





4 On 4WD vehicles, remove the transfer case. See .
5 Use a transmission jack to support the transmission.
6 Remove the 6 crossmember bolts.





7 Remove the 2 transmission mount nuts, then remove the crossmember.





8 Remove the transmission mount.

- Remove the 2 bolts.
- Reposition the exhaust mounting bracket.
1 Lower the transmission to access extension housing bolts.
2
NOTE:Remove sealant from mating surfaces.
NOTE:Two wheel drive (2WD) shown, four wheel drive (4WD) similar.
Remove the 8 bolts and the extension housing.






Installation

1
NOTE:Install a 2 mm (0.07 in) bead of sealant on the extension housing mating surface.
Install the extension housing and the 8 bolts.

- Tighten to 39 Nm (4.0 kgf-m, 29 lb-ft).
1 Install the transmission mount.

- Position the exhaust bracket.
- Install the 2 bolts.
- Tighten to 98 Nm (10 kgf-m, 72 lb-ft).
1 Position the crossmember and install the 6 bolts and nuts.

- Tighten to 63 Nm (6.4 kgf-m, 46 lb-ft).
1 Remove the transmission jack.
2 Install the 2 nuts.

- Tighten to 98 Nm (10 kgf-m, 72 lb-ft).
1 On 4WD vehicles, install the transfer case. See .
2 Install the rear propeller shaft.
3 Refill the transmission with the specified amount of transmission fluid. See Service and Repair.
4 Warm up the engine and transmission, inspect for oil leakage and inspect transmission operation.