RAM 1500 Van V8-5.9L VIN Z (1998)
Extension Housing: Service and Repair
REMOVAL
1. Shift transmission into manual low (1) position.
2. Hoist and support vehicle on safety stands.
3. Mark propeller shaft and axle yoke for alignment reference. Then disconnect and remove shaft.
4. Remove vehicle speed sensor.
5. Remove bolts attaching extension housing to rear support.
6. Using a suitable lifting device, raise transmission off rear mount.
7. Remove rear crossmember.
8. Remove bolts holding extension housing to transmission case.
9. Verify that transmission is in 1 position. Park lock rod is easier to disengage in this position.
10. Remove access plate and gasket from underside of extension housing.
Rear Bearing Retaining Ring
11. Using a snap ring plier, spread retaining ring holding rear bearing in extension housing.
12. While spreading retaining ring, pull extension away from transmission case.
13. Separate extension housing from vehicle.
INSTALLATION
Before installing the extension housing, verify that all gasket sealing surfaces are clean.
1. Position new gasket on housing. Use petroleum jelly to hold gasket in place.
2. Install locating ring in extension housing, if removed.
3. Slide housing onto output shaft.
4. Insert park rod past sprag and slide housing onto shaft unlit the retaining ring contacts the rear bearing.
5. Spread rear bearing retaining ring.
6. Push extension housing forward until fully seated against transmission case. Release locating ring and verify that it is fully seated in rear bearing.
7. Install bolts to hold extension housing to transmission case. Tighten bolts to 43 Nm (32 ft. lbs.) torque.
8. Install gasket and access plate on underside of extension housing.
9. Install rear crossmember.
10. Remove support lift from under transmission.
11. Install bolts to hold extension housing to rear mount. Tighten bolts to 68 Nm (50 ft. lbs.) torque.
12. Install speed sensor.
13. Align and install propeller shaft.
14. Lower vehicle.
15. Top off transmission fluid level if necessary and road test to verify repair.
