Extension Housing: Service and Repair

REMOVAL
WARNING: On vehicles equipped with an auxiliary battery, both the negative and positive battery cables must be disconnected.

1. Disconnect the battery.
2. Raise and support the vehicle.
3. Remove the driveshaft.
4. Remove the transmission-mounted parking brake assembly (if so equipped).





5. Remove the transmission insulator and retainer-to-crossmember retaining nuts.





6. Secure the (A) Highlift Transmission Jack with the (B) E40D Transmission Jack Adapter to the (C) transmission.





7. Raise the transmission jack until the (A) transmission insulator and retainer studs are separated from the (B) transmission support crossmember.





8. Remove the (A) bolts and the (B) transmission insulator and retainer.





9. Disconnect the (A) harness connector and position it aside. Remove the (B) bolt and the (C) vehicle speed sensor (VSS).





10. With a suitable drain pan properly positioned, remove the 8 (A) bolts, the (B) stud and the (C) extension housing.

NOTE: As the fasteners are removed, note the size of each for proper location during installation.





11. Remove and discard the extension housing gasket.





INSTALLATION
1. Place the new extension housing gasket on the extension housing.

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.





2. Install the (A) extension housing, the 8 (B) bolts and the (C) stud.

NOTE: Make sure the fasteners are installed in their proper locations as noted during removal.





3. Install the (A) vehicle speed sensor (VSS) and the (B) bolt. Connect the (C) harness connector.





4. Install the (A) transmission insulator and retainer and the (B) bolts.





5. Lower the transmission jack while aligning the (A) transmission insulator and retainer studs with the holes in the (B) transmission support crossmember. Allow the full weight of the transmission to rest on the transmission support crossmember.





6. Install the transmission insulator and retainer-to-crossmember retaining nuts.





7. Remove the (A) Highlift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission.





8. Reinstall the transmission fluid pan-to-case retaining bolts removed to install the jack adapter.
9. Install the transmission-mounted parking brake assembly (if so equipped).
10. Install the driveshaft.
11. Remove the supports and lower the vehicle.
12. Connect the battery.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

13. Fill the transmission to the specified level with MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent.