Extension Housing: Service and Repair

EXTENSION HOUSING AND GASKET REMOVAL/INSTALLATION
1. Disconnect the battery ground cable.
2. Raise and support the vehicle.

Note To maintain initial propeller shaft balance, mark the rear propeller shaft yoke and axle flange so they may be installed in their original position.

3. Mark the rear propeller shaft.
4. Remove the rear propeller shaft.
5. Remove transfer case (4x4 only).
6. Remove wire harness locators from extension housing wire bracket (4x4 only).
7. Remove the transmission mount nuts.
8. Raise and support the transmission.





9. Remove the transmission mount.





4X2





4X4
10. Remove the screws and stud(s).

Note The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal of the extension housing.





4X2





4X4
11. Remove the extension housing and discard extension housing gasket.





12. Clean the extension housing and install new extension housing gasket. Ensure that the parking pawl is correctly installed.

Caution Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup.





4X2





4X4
13. Position the extension housing and install screws and stud(s).
14. Position transmission mount on extension housing and install screws.
Tightening torque
68 - 95 Nm (6.9 - 9.7 kgf.m, 50 - 70 ft. lbs.)
15. Install transmission mount into crossmember and tighten transmission mount nuts.
Tightening torque
98 - 132 Nm (10 - 13.5 kgf.m, 73 - 97 ft. lbs.)
16. Install transfer case (4x4 only).
17. Align and install rear propeller shaft.
18. Connect battery negative cable.
19. Fill transmission to proper fluid level.
- Use Mazda AFT TYPE 5 fluid.
20. Check for proper transmission operation.

EXTENSION HOUSING AND GASKET (4X4) REMOVAL/INSTALLATION
1. Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Remove the rear propeller shaft.
4. Remove the transfer case.
5. Remove the wire harness locations from the extension housing wire bracket.
6. Remove the transmission mount nuts.
7. Raise and support the transmission.
8. Remove the transmission mount-to-extension housing bolts (1).





9. Remove the transmission mount (2).





10. Remove the six extension housing bolts and studs.

Note The parking pawl, parking pawl return spring and parking pawl shaft may fall out during removal of the extension housing.





11. Remove the extension housing. Discard the extension housing

Caution Make sure the parking lever actuating rod is correctly seated into the case parking rod guide cup.





12. Position the extension housing and install the six extension housing bolts and studs.
13. Position the transmission mount on the extension housing and install bolts.
Tightening torque
68 - 95 Nm (6.9 - 9.7 kgf.m, 50 - 70 ft. lbs.)
14. Install the transmission mount into the crossmember and tighten the transmission mount nuts.
Tightening torque
98 - 132 Nm (10 - 13.5 kgf.m, 73 - 97 ft. lbs.)
15. Install the transfer case.
16. Install the rear propeller shaft.
17. Connect the battery ground cable.
18. Fill the transmission to proper fluid level and check for proper transmission operation.
- Use Mazda ATF TYPE 5 fluid MERCON(R)V.