Extension Case Replacement 2WD

Tools Required

1. Remove the following components from the extension case:

1.1.

One bolt

1.2.	The speedometer driven gear case




2. Remove the following components from the extension case:

2.1.	The two select return spring bolts

2.2.	The two select return springs

2.3.	The two select guide pins

3. Use the J 23129 and the J 6125-1B in order to remove the extension case oil seal from the extension case.
4. Clean the extension case-to-upper and lower case mating surfaces.
5. Inspect the extension case for the following conditions and replace as necessary:

•

Cracks

•

Porosity

6. Inspect the select return springs for the following conditions and replace as necessary:

•	Distortion

•

Weakness

Tools Required

1. Apply J 36850 to the extension case oil seal surface.
2. Use the J 37750 and a hammer in order to install the new extension case oil seal.
3. Install the following components into the extension case:

3.1.	The two select guide pins

3.2.	The two select return springs

3.3.	The two select return spring bolts

Tighten
Tighten the select return spring bolts to 23 N·m (17 lb ft).

3.3.

Refer to 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. in General Information.

4. Apply J 36850 to the speedometer driven gear case O-ring.



5. Install the speedometer driven gear case into the extension case.

Secure the gear case with one bolt.

Tighten
Tighten the speedometer driven gear case retaining bolt to 12 N·m (106 lb in).