Extension Housing: Service and Repair

EXTENSION HOUSING (2 WHEEL DRIVE)

REMOVAL

1. Mark the propeller shaft and rear axle yoke for assembly alignment reference.

2. Remove the propeller shaft.

3. Remove the speedometer cable and adapter from the extension housing.

4. Support the transmission with a transmission jack.

5. Remove the rear crossmember.

6. Remove the extension housing-to-transmission case bolts.

7. Remove the transmission rear bearing cover plate from the extension housing.

8. Expand the rear bearing snap ring with snap ring pliers and carefully tap the extension housing off the bearing and output shaft.

9. Remove the rear bearing snap ring from the housing.

INSTALLATION

1. Place the rear bearing snap ring in the extension housing.

2. Install the extension housing on the output shaft.

3. Expand the rear bearing snap ring and carefully tap the extension housing into place.

4. Install and tighten the extension housing-to-transmission case bolts to 33 Nm (24 ft. lbs.) torque.

5. Install the rear bearing cover ptate on the extension housing.

6. Install the rear crossmember. Tighten the crossmember-to-sill bolts to 41 Nm (30 ft. lbs.) torque. Tighten the rear engine cushion adapter-to-transmission bolts as follows. Tighten 7/16 - 14 bolts to 44 Nm (32 ft. lbs.) and tighten 5/16 - 18 bolts to 15 Nm (11 ft. lbs.).

7. Remove the transmission jack.

8. Install the speedometer cable and adapter.

9. Install and align the propeller shaft. Tighten the U-joint clamp bolts to 19 Nm (170 in. lbs.) torque.

10. Check and adjust the transmission fluid level as necessary.