Extension Housing Gasket

Extension Housing Gasket











Removal

1. WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury.

With the vehicle in NEUTRAL, position it on a hoist.

2. NOTE: The output shaft and driveshaft are a balanced assembly.

Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly.





3. Remove the 4 driveshaft bolts.





4. Slide the drive shaft back enough to index-mark the driveshaft, output shaft and the extension housing. Separate the driveshaft from the transmission.





5. Remove the rear transmission insulator nuts.





6. Disconnect the RH heated oxygen sensor (HO2S) sensor connector.





7. Disconnect the RH catalyst monitor connector.





8. Remove the bolts from the RH exhaust flange.





9. Remove the 2 bolts and the RH catalytic converter.





10. Disconnect the LH HO2S connector.





11. Disconnect the LH catalyst monitor connector.





12. Remove the bolts from the LH exhaust flange.





13. Remove the 2 bolts and the LH catalytic converter.





14. Install a suitable transmission jack.
15. Remove the RH side crossmember bolts.





16. Disconnect the LH side crossmember.
1. Loosen but do not remove the LH side crossmember bolts.
2. Remove the LH side crossmember bolt.





17. Remove the bolts and remove the parking brake cable bracket and position aside.





18. NOTE: The crossmember is a press fit in the crossmember pocket, it may be necessary to pry the crossmember out of the crossmember pocket. Be careful not to damage the crossmember. Only the RH side of the crossmember will need to be lowered in order to gain access to the rear extension housing.

Lower the RH side of the crossmember.





19. Remove the rear transmission insulator bolts.





20. Remove the LH and RH catalyst monitor connector retainers.





21. Remove the rear extension housing bolts and the housing.





22. Remove the extension housing gasket.





Installation
1. Install a new extension housing gasket.





2. Install the extension housing and the bolts.
^ Tighten to 28 Nm (21 lb-ft).





3. Install the LH and RH catalyst monitor connector retainers.





4. Install the rear transmission insulator and bolts.
^ Tighten to 90 Nm (66 lb-ft).





5. Position the RH crossmember and install the bolts.
^ Tighten to 70 Nm (52 lb-ft).





6. Install the LH side crossmember bolt.
^ Tighten to 70 Nm (52 lb-ft).





7. Install the parking brake cable bracket.
^ Tighten to 55 Nm (41 lb-ft).





8. Lower the transmission onto the crossmember and install the rear transmission insulator nuts.
^ Tighten to 30 Nm (22 lb-ft).





9. Remove the transmission jack.
10. Install a new gasket and position the RH catalytic converter assembly in place and loosely install the bolts. Do not tighten the bolts at this time.





11. Install the RH exhaust flange nuts.
^ Tighten to 48 Nm (35 lb-ft).





12. Tighten the RH exhaust bolts.
^ Tighten to 40 Nm (30 lb-ft).





13. Connect the RH HO2S connector.





14. Connect the RH catalyst monitor connector.





15. Install a new gasket and position the LH catalytic converter assembly in place and loosely install the bolts. Do not tighten the bolts at this time.





16. Install the LH exhaust flange nuts.
^ Tighten to 48 Nm (35 lb-ft).





17. Tighten the LH exhaust bolts.
^ Tighten to 40 Nm (30 lb-ft).





18. Connect the LH HO2S sensor connector.





19. Connect the LH catalyst monitor connector.





20. NOTE: The output shaft and the driveshaft are a balanced assembly.

Install the driveshaft.
^ Align the index marks and position the driveshaft on the transmission.
^ Install the driveshaft.





21. NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original position that was marked during removal.

Install the 4 retaining bolts.
^ Tighten to 103 Nm (76 lb-ft).





22. Lower the vehicle.

23. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury.

Check the level of the transmission fluid. Add clean automatic transmission fluid as necessary.