Extension Housing: Service and Repair

EXTENSION HOUSING YOKE SEAL

Replacement
(1) Mark parts for reassembly then disconnect propeller shaft at rear universal joint. Carefully pull shaft yoke out of the transmission extension housing. Be careful not to scratch or nick ground surface on sliding spline yoke during removal and installation of the shaft assembly.






(2) Remove oil seal with Tool C-3985 (Fig. 4). Removal and Replacement






(3) To install a new seal, position seal in opening of extension housing and drive it into the housing with Tool C-3995 or C-3972 (Fig. 5).
(4) Carefully guide front universal joint yoke into extension housing and on the mainshaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion shaft yoke.


EXTENSION HOUSING BUSHING AND OUTPUT SHAFT BEARING

Extension Removal
(1) Mark parts for reassembly then disconnect propeller shaft at rear universal joint. Carefully pull shaft assembly out of the extension housing.






(2) Remove oil seal with Tool C-3985 (Fig. 4).






(3) Remove speedometer pinion and adapter assembly (Fig. 1). Drain approximately two quarts of fluid from the transmission.
(4) Remove bolts securing extension housing to the crossmember. Raise transmission slightly with service jack, then remove center crossmember and support assembly.
(5) Remove extension housing to transmission bolts.

Console Shift: Remove two bolts securing gearshift torque shaft lower bracket to extension housing. Swing bracket out of the way for extension housing removal.

When removing or installing extension housing (step 6), the gearshift lever must be in "1" (first) position. This positions parking lock control rod rearward so it can be disengaged or engaged with the parking lock sprag.

Fig. 7 Extension housing snap ring removal:

6. Remove two screws, plate and gasket from bottom of extension housing mounting pad, then spread snap ring from output shaft bearing, Fig. 7. With snap ring spread as far as possible, Carefully pull extension housing rearward, to remove parking lock control rod knob past the parking sprag, than remove the housing.

Bearing Replacement






(1) Using heavy duty snap ring pliers, remove output shaft bearing rear snap ring and remove bearing from the shaft (Fig. 7).
(2) Install a new bearing on shaft with outer race ring groove toward front, then install rear snap ring. A-727 has a snap ring in front of bearing, A-904 family does not.

Bushing Replacement






(1) A-904: Press or drive out bushing with Tool C-3996 (Fig. 8).
A-727: Remove bushing in the same manner with Tool C-3974.
(2) A-904: Slide a new bushing on installing end of Tool C-3996. Align oil hole in bushing with oil slot in the housing, then press or drive bushing into place (Fig. 8).






A.727: Using Tool C-3974, install a new bushing in same manner. Fig.(3)






(3) A-904: Drive a new oil seal into housing with Tool C-3995 (Fig. 5). A-727: Using Tool C-3972, install a new oil seal in same manner.

Extension Installation






(1) Place a new extension housing gasket on the transmission case. Position output shaft bearing retaining snap ring in extension housing. Slide extension housing on output shaft guiding the parking lock control rod knob past the parking sprag. While spreading large snap ring in housing (Fig. 6), carefully tap housing into place, then release the snap ring. Make sure snap ring is fully seated in bearing outer race ring groove.
(2) Install and tighten extension housing bolts to 24 ft. lbs. (33 N.m).
(3) Install gasket, plate, and two screws on bottom of the extension housing mounting pad.
(4) Install center crossmember and rear mount assembly, tighten retaining bolts. Lower transmission to install extension housing to support bolts and tighten to 50 ft.lbs. (68 N.m).

Console Shift: Align gearshift torque shaft lower bracket with the extension housing. Install the two retaining bolts and tighten securely.
(5) Install the speedometer pinion and adapter.
(6) Carefully guide front universal joint yoke into extension housing and on the output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion shaft yoke.
(7) Add fluid to transmission to bring up to proper level.

GOVERNOR AND PARKING GEAR

Removal
(1) Remove extension housing and output shaft bearing as previously described.






(2) Carefully pry snap ring from weight end of governor valve shaft (Fig. 9). Slide valve and shaft assembly out of governor body.
(3) Remove large snap ring from weight end of governor body, lift out governor weight assembly.






(4) Remove snap ring from inside governor weight, remove inner weight and spring from the outer weight. Figure 10 shows a disassembled view of the governor assembly.
(5) Remove snap ring from behind governor body then slide governor and support assembly off the output shaft. Remove the four bolts and separate governor body and screen from the parking gear.

Cleaning and Inspection
Figure 10 shows a disassembled view of the governor assembly.
Inspect all parts for burrs and wear. Inspect inner weight for free movement in outer weight, and outer weight for free movement in governor body. Inspect valve for free movement in governor body. The weights and valve should fall freely in the bores when clean and dry. Rough surfaces may be removed with crocus cloth. Wash governor screen. Inspect governor seal rings for wear on sides and outside diameter. Inspect governor weight spring for distortion. Inspect lugs on support gear for broken edges or other damage. Thoroughly clean all governor parts in clean solvent and test for free movement before assembly.

Assembly
Assemble governor weights and spring, and secure with snap ring inside of large governor weight. Place weighted assembly in governor body and install snap ring.

Installation
(1) Assemble governor body and screen to the support and tighten bolts finger tight. Make sure oil passage of governor body aligns with passage in the support.






(2) Position support and governor assembly on the output shaft. Align assembly so valve shaft hole in governor body aligns with hole in the output shaft, then slide assembly into place. Install snap ring behind governor body (Fig. 9). Tighten the body to support bolts to 100 in. lbs. (11 N.m). The support bolts have a self-locking nylon patch and can be reused.
(3) Assemble governor weights and spring, and secure with snap ring inside of large governor weight. Place weight assembly in governor body and install snap ring.
(4) Place governor valve on the valve shaft, insert assembly into the body and through governor weights. Install valve shaft retaining snap ring. Inspect valve and weight assembly for free movement after installation.
(5) Install output shaft bearing and extension housing.

PARKING LOCK COMPONENTS






Removal
(1) Remove extension housing as previously described.
(2) Slide shaft out of extension housing to remove(2) Slide shaft out of extension housing to remove the parking sprag and spring (Fig. 11). Remove snap ring and slide the reaction plug and pin assembly out of the housing.
(3) To replace the parking lock control rod, Refer to parking pawl, A/T Parking Pawl Valve Body

Inspection
Inspect sprag shaft for scores and free movement in the housing and sprag. Inspect sprag and control rod springs for distortion and tension. Inspect square lug on sprag for broken edges, also lugs on parking gear for damage. Inspect knob on end of control rod for nicks, burrs, and free turning.






Assembly
(1) Install reaction plug and pin assembly in the housing and secure with snap ring (Fig. 11).
(2) Position sprag and spring in housing and insert the shaft. Make sure square lug on sprag is toward parking gear, and spring is positioned so it moves sprag away from the gear.
(3) Install extension housing.