Extension Housing Installation (5L40-E/5L50-E AWD Including XLR)

Tools Required 

J 44765  Seal Installer. See Special Tools .

Fig 1: Inspecting Inner & Outer Bearings
Courtesy of GENERAL MOTORS CORP.
1. Inspect both inner and outer output shaft bearings for the following:
   • Damaged cage
   • Roller pitted
2. If either bearing is damaged, replace the extension housing.
Fig 2: Measuring Dimension B
Courtesy of GENERAL MOTORS CORP.
3. Rotate the transmission 90 degrees.
4. Measure from the bottom to the face of the bearing. Record this as dimension B. Refer to the End Play Specifications (5L40-E)  or End Play Specifications (5L50-E)  to determine the correct washer size.
Fig 3: Installing Extension Housing
Courtesy of GENERAL MOTORS CORP.
5. Install the extension housing gasket (25) onto the extension housing (27).
6. Install the extension housing (27) onto the case.
NOTE: Refer to Fastener Notice in Cautions and Notices.
7. Install the extension housing bolts (35).

   Tighten:  Tighten the extension housing bolts to 22 N.m (16 lb ft).

Fig 4: Installing Prop Shaft Flange Seal
Courtesy of GENERAL MOTORS CORP.
IMPORTANT: Install the seal onto the tool before installing into the case to prevent damage to the seal.
8. Using J 44765  install the prop shaft flange seal (29) - 5L40-E/5L50-E AWD. See Special Tools .
Fig 5: Installing Prop Shaft Flange Seal (XLR Only)
Courtesy of GENERAL MOTORS CORP.
9. Using J 46741  install the prop shaft flange seal (68) - XLR only. See Special Tools .