Attachment III - Technical Instructions
Retaining Ring Technical InstructionsExtension Assembly Removal
1. Raise truck on hoist.
NOTE:
To maintain driveshaft balance, mark the rear of the driveshaft and the axle companion flange so they are reinstalled in their original position.
2. Disconnect driveshaft from rear axle flange and remove from transmission.
3. Remove the speedometer cable and speed-o-gear from the extension housing.
4. Remove transmission insulator and the retainer assembly nuts.
5. Position a jack under the transmission and raise it enough to remove the weight from the insulator and retainer assembly.
6. Position a drain pan under the rear of the transmission case.
7. Remove two bolts from extension housing and remove the insulator and retainer assembly.
8. Remove the extension housing to case bolts.
9. Slide the extension housing off the output shaft and allow the fluid to drain. (Discard old Extension Housing.)
10. Remove spline seal from output shaft and Discard (See Figure 1).
11. Remove retaining ring from shaft and Discard. Do not reuse ring (See Figure 1).
CAUTION
If parking gear moves rearward, the thrust washer in front of the parking gear can become dislodged. Push the parking gear forward and pull the output shaft rearward to retain thrust washer and expose entire retaining ring groove.
CAUTION
The retaining ring must not be over stressed during installation. A special installation aid has been provided to prevent this from happening during installation. Flat nose snap ring pliers should be used to install ring.
12. Remove installation aid with retaining ring from package. Hold ring in installation aid opposite opening and place installation aid on output shaft, just before speed-o-gear, with ring facing transmission. (Retaining ring ends must be in installation aid opening.) (See Figure 2)
13. Hold snap ring pliers parallel to output shaft and expand ring within installation aid.
14. Slide ring over speed-o-gear (See Figure 3) and release ring when installation aid is against parking gear (See Figure 4).
15. Inspect retaining installation (See Figure 5). If ring is not seated, use opposite face of installation aid to seat ring in groove (See Figure 6). Remove installation aid from output shaft.
16. Check to make sure ring is secure (doesn't rotate in groove). If ring rotates, remove and discard it. Repeat steps 11 through 16 to install second ring provided in kit.
Extension Assembly Installation
1. Visually inspect parking pawl, pin and spring for proper position (See Figure 7).
2. Clean the mounting surface on the extension housing and transmission case. Put a new gasket on the new extension housing.
3. Install the new extension housing and secure it to the case with attaching bolts. Tighten to 20-29 ft.-lb. (30-40 N-m)
4. Reinstall transmission insulator and retainer assembly to extension housing.
NOTE:
Install the insulator with the word rear to rear of vehicle. Lower transmission.
5. Remove transmission jack.
6. Install the insulator and retainer assembly nuts. Tighten to 50-70 ft.-lb. (70-100 N-m).
7. Attach the speedometer cable and speed-o-gear to the extension housing with the attaching screw. Tighten to 20-25 ft.-lb. (30-35 N-m).
8. Align marks and reinstall driveshaft into the transmission and secure at the rear axle companion flange with attaching bolts and nuts. Tighten to 8-15 ft.-lb. (10-20 N-m).
9. Lower truck and check transmission fluid level, add as required.
10. Visually inspect transmission case and extension housing for leaks.