GM Service Manual Online
For 1990-2009 cars only

Extension Housing Installation 2WD

Special Tools

J 44765 Seal Installer

For equivalent regional tools, refer to Special Tools.


    Object Number: 1516269  Size: SH
  1. Inspect both inner and outer output shaft bearings for the following:
  2. • Damaged cage
    • Roller pitted
  3. If either bearing is damaged replace extension housing.

  4. Object Number: 816754  Size: SH
  5. Rotate the transmission 90 degrees.
  6. Measure from the bottom to the face of the ouput shaft. Record this as dimension B. Refer to the End Play Specifications to determine the correct washer size.

  7. Object Number: 1646681  Size: SH
  8. Install the input and reaction carrier washer (22).
  9. Install the input and reaction carrier thrust bearing (23) onto the extension housing.
  10. Install the extension housing gasket (25) onto the extension housing (27).
  11. Install the extension housing (27) onto the case.
  12. Caution: Refer to Fastener Caution in the Preface section.

  13. Install the extension housing bolts (35). Tighten the extension housing bolts to 22 N·m (16 lb ft).

  14. Object Number: 802136  Size: SH

    Note: Install the seal onto the tool before installing into the case to prevent damage to the seal.

  15. Using J 44765 seal installer install the prop shaft flange seal (29).

Extension Housing Installation AWD

Special Tools

J 46741 AWD Seal Installer

For equivalent regional tools, refer to Special Tools.


    Object Number: 1516271  Size: SH
  1. Inspect both inner and outer output shaft bearings for the following conditions:
  2. • Damaged cage
    • Roller pitted
  3. If either bearing is damaged, replace the extension housing.

  4. Object Number: 952131  Size: SH
  5. Rotate the transmission 90 degrees.
  6. Measure from the bottom to the face of the bearing. Record this as dimension B. Refer to End Play Specifications to determine the correct washer size.

  7. Object Number: 952124  Size: SH
  8. Install the input and reaction carrier thrust bearing (69).
  9. Install the extension housing gasket (25) onto the extension housing (27).
  10. Install the extension housing (27) onto the case.
  11. Caution: Refer to Fastener Caution in the Preface section.

  12. Install the extension housing bolts (35). Tighten the extension housing bolts to 22 N·m (16 lb ft).

  13. Object Number: 1785040  Size: SH

    Note: Install the seal onto the tool before installing into the case to prevent damage to the seal.

  14. Using J 46741 AWD seal installer install the prop shaft flange seal (29) - 5L40-E/5L50-E AWD.