Case Extension Replacement 3.5L Twin Cam V6 LX5

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Disconnect the right drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle.
4. Remove the right (rear) engine mount. Refer to Engine Mount Replacement in Engine Mechanical - 3.5L.
5. Remove the right (rear) engine mount. bracket. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.5L..
6. Remove the transaxle brace. Refer to Transmission Brace Replacement .
7. Remove the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .



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



10. 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

1. If removed, install the drive axle seal. Refer to Front Wheel Drive Shaft Oil Seal Replacement .



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

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the case extension housing bolts (5).

Tighten
Tighten the case extension housing bolts (5) to 36 N·m (27 lb ft).

4. Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .
5. Install the transaxle brace. Refer to Transmission Brace Replacement .
6. Remove the right (rear) engine mount. bracket. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.5L..
7. Remove the right (rear) engine mount. Refer to Engine Mount Replacement in Engine Mechanical - 3.5L.
8. Connect the right drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle.
9. Lower the vehicle.
10. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

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

11. Adjust the fluid level. Refer to Transmission Fluid Check , Approximate Fluid Capacities in Maintenance and Lubrication and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
12. Inspect for completion of the repairs.
13. Inspect for fluid leaks.

Case Extension Replacement 3800 L36

Caution: Before servicing any electrical component, the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components.

1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the right drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle.
4. Remove the transaxle brace. Refer to Transmission Brace Replacement .
5. Remove the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .



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



8. 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

1. If removed, install the drive axle seal. Refer to Front Wheel Drive Shaft Oil Seal Replacement .



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

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the case extension housing bolts (5).

Tighten
Tighten the case extension housing bolts (5) to 36 N·m (27 lb ft).

4. Install the vehicle speed sensor. Refer to Vehicle Speed Sensor Replacement .
5. Install the transaxle brace. Refer to Transmission Brace Replacement .
6. Connect the right drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle.
7. Lower the vehicle.
8. Connect the battery ground (negative) cable. Refer to Battery Negative Cable Disconnection and Connection in Engine Electrical.

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

9. Adjust the fluid level. Refer to Transmission Fluid Check , Approximate Fluid Capacities in Maintenance and Lubrication and Fluid and Lubricant Recommendations in Maintenance and Lubrication.
10. Inspect for completion of the repairs.
11. Inspect for fluid leaks.