Extension Housing: Service and Repair

Removal Procedure

^ Tools Required
- J 42066 Rear Hub Holding Tool
- J 6125-1B Slide Hammer
- J 23129 Axle Boot Remover
- J 36797 Getrag Axle Output Shaft Seal Installer





1. Remove the transmission mount. Refer to Transmission Mount.
2. Remove the propeller shaft coupling bolts.
3. Remove the propeller shaft coupling from flange. Use a screwdriver to pry propeller shaft coupling away from flange.





4. Install the J 42066 onto the drive flange using nuts and bolts supplied with tool.
5. While holding the J 42066 and using a 30 mm deepwell socket to remove the flange nut.
6. Discard the nut.





7. Remove the drive flange (49) from transmission output shaft.





8. Using the J6125-1B and the J23129 remove the case extension seal (50) from the transmission (43).





9. Remove the catalytic converter support bracket bolts (1) and bracket.





10. Disconnect the transmission speed sensor electrical connector.
11. Remove the transmission speed sensor bolt and sensor with seal.
Use hand pressure to twist sensor while pulling outward. Do not pry on sensor.





12. Remove rear oxygen sensor harness clips (1112) from the case extension.
13. Remove the case extension bolts (52).
14. Remove the case extension (43).
15. Remove the case extension gasket (42).

Installation Procedure





1. Install the new case extension gasket (42).
2. Install the case extension (43).

Notice: Refer to Fastener Notice in Service Precautions.

3. Install the case extension bolts (52).
^ Tighten the bolts to 32 Nm (23 ft. lbs.).
4. Install the rear oxygen sensor harness clips (112) to the case extension.





5. Install the transmission speed sensor seal (44), sensor (45) and the bolt (46).
^ Tighten the speed sensor bolt to 9 Nm (78 inch lbs.).
6. Connect the transmission speed sensor electrical connector.





7. Install the catalytic converter support bracket bolts (1) and bracket.





8. Using the J 36797 install the new seal (50) into the case extension.





9. Install the drive shaft flange, washer, and the new nut onto the output shaft.





10. Install the J 42066 onto the drive flange using nuts and bolts supplied with tool.

Notice: Refer to Fastener Notice in Service Precautions.

11. While holding the J 42066 and using a 30 mm deepwell socket to tighten the flange nut.
^ Tighten the drive flange nut to 100 Nm (74 ft. lbs.).





12. Install the propeller shaft coupling to drive flange.
13. Install the propeller shaft coupling bolts.
^ Tighten the propeller shaft coupling bolts to 95 Nm (70 ft. lbs.).
14. Install the transmission mount. Refer to Transmission Mount.
15. Inspect and adjust the transmission fluid level. Refer to Transmission Fluid Checking Procedure.