Extension Housing: Service and Repair

REMOVE OR DISCONNECT
^ Tools Required:
- J 6125-B Slide Hammer
- J 23129 Converter Housing Seal and Extension Housing Oil Seal Remover

1. Raise and suitably support vehicle.
2. Place a drain pan or suitable container under transmission fluid pan.
3. Transmission fluid pan and gasket and drain transmission fluid.
4. Install transmission fluid pan and new gasket onto transmission to support transmission assembly on hydraulic jack; secure with twelve bolts (3L30, 3-Speed).
- Tighten transmission fluid pan bolts to 13 Nm (115 inch lbs.).
5. Remove drain plug from under transmission fluid pan (03-72LE, 4-Speed).
6. Support transmission with a suitable hydraulic jack.
7. Transfer case from vehicle.
8. Two bolts, two nuts and exhaust pipe bracket from transfer adapter case and catalytic converter.





9. Seven bolts, transfer adapter case and gasket from transmission case.





10. Parking lock pawl, parking lock pawl shaft and parking lock pawl return spring from transfer adapter case (3L30, 3-Speed).





11. Transfer adapter case seal from transfer adapter case using J 6125-B with J 23129.

Clean
- Transfer adapter case and transmission case mating surfaces.

Inspect
- Transfer adapter case for cracks or other damage. Replace as necessary.

INSTALL OR CONNECT
^ Tools Required:
- J 35538 Axle Shaft Seal Installer
- J 36850 Transjel(R) Transmission Assembly Lubricant

1. Apply a thin coat of J 63850 to the transfer adapter case seal surface.





2. New transfer adapter case seal into the transfer adapter case using J 35538.
3. Apply J 36850 to the new transfer adapter case seal lip.
4. Parking lock pawl return spring, parking lock pawl shaft and parking lock pawl into transfer adapter case (3L30, 3-Speed).
5. New transfer adapter case gasket and transfer adapter case to transmission case; secure with seven bolts.
- Tighten transfer adapter case bolts to 31 Nm (23 ft. lbs.).
6. Exhaust pipe bracket to transfer adapter case and catalytic converter; secure with two bolts and two nuts.
- Tighten exhaust pipe bracket bolts and nuts to 23 Nm (17 ft. lbs.).
7. Transfer case into vehicle.
8. Remove hydraulic jack from under transmission.
9. Lower vehicle.
10. Refill transmission as necessary:
A. Place vehicle on a level surface.
B. Remove fluid level indicator.
C. Add approximately 1.5 liters (1.6 qts.) of Dexron(R)-III automatic transmission fluid into fluid filler tube.
D. Install fluid level indicator into fluid filler tube.
E. Apply parking brake and block vehicle wheels.
F. With selector lever in "P" position, start engine. DO NOT race engine.
G. Run engine at idle and move selector lever through each range and return to the "P" position.
H. With engine running at idle, remove fluid level indicator from filler tube and wipe indicator off.
I. Reinsert fluid level indicator into filler tube making sure it is seated in its original position.
J. Remove the indicator and check the fluid level. The level should be between the "FULL HOT" and "LOW HOT" marks. If the level is below the "LOW HOT" mark, add fluid to bring the level to the "FULL HOT" mark. Bringing the fluid level from the "LOW HOT" mark to the "FULL HOT" mark requires 0.3 liters (0.3 qts.) of fluid. Use Dexron(R)-III automatic transmission fluid.
K. Conduct a road test and check transmission level. Refer to CHECKING FLUID LEVEL (NORMAL OPERATING TEMPERATURE).