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Extension Case (2WD): Installation

  1. Clean mating surfaces of transmission and extension case.
  2. Confirm that fluid guide pipe "1" is installed into the extension case properly. See Fig 1 .
  3. Install new gasket and extension case "2" to transmission. Tighten bolts "1" to specification. See TORQUE SPECIFICATIONS  . See Fig 2 .
  4. Install rear mounting and tighten bolts to specified torque. See Figure .
  5. Connect A/T output speed sensor connector. See Fig 3 .
  6. Connect vehicle speed sensor connector.
  7. Install rear drive shaft. See appropriate DRIVE SHAFTS AND UNIVERSAL JOINTS article in DRIVELINE/AXLES.
  8. Lower vehicle.
  9. Add ATF and check fluid level. See CHECKING FLUID LEVEL  under LUBRICATION.
  10. Connect battery negative cable to battery.
Fig 1: Installing Fluid Guide Pipe Into Extension Case
G00297972Courtesy of SUZUKI OF AMERICA CORP.
Fig 2: Installing Extension Case (2WD)
G00297973Courtesy of SUZUKI OF AMERICA CORP.
Fig 3: Identifying Output Speed Sensor
G00297991Courtesy of SUZUKI OF AMERICA CORP.