Extension Housing: Service and Repair

EXTENSION HOUSING AND GASKET REMOVAL / INSTALLATION

1. 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.

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





8. Remove the transmission mount.





4x2





4x4

9. 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

10. Remove the extension housing and discard extension housing gasket.





11. 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

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

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





7. Remove the transmission mount-to-extension housing bolts (1).
8. Remove the transmission mount (2).





9. 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.





10. Remove the extension housing. Discard the extension housing gasket.

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





11. Position the extension housing and install the six extension housing bolts and studs.
12. 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.)
13. 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.)
14. Install the transfer case.
15. Install the rear propeller shaft.
16. Fill the transmission to proper fluid level and check for proper transmission operation.
- Use equivalent.