Extension Housing: Service and Repair

Case Extension Replacement

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle Service and Repair.
2. Disconnect the right drive axle from the transaxle. Refer to Front Wheel Drive Shaft Replacement Service and Repair.
3. Remove the transaxle brace. Refer to Transmission Brace Replacement Transmission Brace Replacement.
4. Remove the vehicle speed sensor. Refer to Input Speed Sensor Replacement Service and Repair.




5. Remove the case extension housing bolts (5).
6. Remove the case extension housing (6) with the axle seal and the O-ring (8).




7. Inspect the case extension housing (6) for the following conditions:

* A damaged or porous sealing surface for the case extension seal
* A damaged or porous sealing surface for the vehicle speed sensor
* A damaged or porous sealing surface for the right drive axle oil seal
* A damaged or porous sealing surface for the case extension housing
* A damaged or worn differential carrier bushing or output shaft bearing
* Damaged bolt holes
* Inspect the drive axle seal and replace if necessary.

Installation Procedure

1. If removed, install the drive axle seal.




2. Install the case extension housing (6) with the axle seal and with the O-ring (8).

Caution: Refer to Fastener Caution Fastener Caution.

3. Install the case extension housing bolts (5) and tighten to 36 Nm (27 lb ft).
4. Install the vehicle speed sensor. Refer to Input Speed Sensor Replacement Service and Repair.
5. Install the transaxle brace. Refer to Transmission Brace Replacement Transmission Brace Replacement.
6. Connect the right drive axle to the transaxle. Refer to Front Wheel Drive Shaft Replacement Service and Repair.
7. Lower the vehicle.

Caution: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle.

8. Adjust the fluid level. Refer to the following information:

* Transmission Fluid Check Testing and Inspection
* Fluid and Lubricant Recommendations Specifications
* Approximate Fluid Capacities Specifications

9. Inspect for completion of the repairs.
10. Inspect for fluid leaks.