Extension Housing Gasket: Removal

WARNING: This page is about a different car, the 2003 Mercury Marauder, 2003 Mercury Grand Marquis, and 2003 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

Position the vehicle on a hoist. Place in NEUTRAL. For additional information, refer to JACKING & HOISTING .

NOTE: The output shaft and driveshaft are a balanced assembly.

Fig 1: Marking Driveshaft Flange And Rear Pinion Flange

G01608278

Courtesy of FORD MOTOR CO.

Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly.
Remove the four driveshaft bolts.

Fig 2: Removing Four Driveshaft Bolts
Courtesy of FORD MOTOR CO.
Index mark the driveshaft and extension housing. Separate the driveshaft from the transmission.

Fig 3: Separating Driveshaft From Transmission
Courtesy of FORD MOTOR CO.
Remove the rear transmission insulator nuts.

Fig 4: Removing Rear Transmission Insulator Nuts
Courtesy of FORD MOTOR CO.
Disconnect the RH HO2S sensor connector.

Fig 5: Disconnecting RH HO2S Sensor Connector
Courtesy of FORD MOTOR CO.
Disconnect the RH catalyst monitor connector.

Fig 6: Disconnecting RH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
Remove the bolts from the RH exhaust flange.

Fig 7: Removing Bolts From RH Exhaust Flange
Courtesy of FORD MOTOR CO.
Loosen the exhaust clamp and remove the RH exhaust pipe.

Fig 8: Loosening Exhaust Clamp And Removing RH Exhaust Pipe
Courtesy of FORD MOTOR CO.
Disconnect the LH HO2S sensor connector.

Fig 9: Disconnecting LH HO2S Sensor Connector
Courtesy of FORD MOTOR CO.
Disconnect the LH catalyst monitor connector.

Fig 10: Disconnecting LH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
Remove the bolts from the LH exhaust flange.

Fig 11: Removing Bolts From LH Exhaust Flange
Courtesy of FORD MOTOR CO.
Loosen the exhaust clamp and remove the LH exhaust pipe.

Fig 12: Loosening Exhaust Clamp And Removing LH Exhaust Pipe
Courtesy of FORD MOTOR CO.
Install a suitable transmission jack.
Remove the RH side crossmember bolts.

Fig 13: Removing RH Side Crossmember Bolts
Courtesy of FORD MOTOR CO.
Disconnect the LH side crossmember.
1. Loosen but do not remove the LH side crossmember bolts.
2. Remove the LH side crossmember bolt.
Fig 14: Disconnecting LH Side Crossmember
Courtesy of FORD MOTOR CO.
Remove the bolts and remove the parking brake cable bracket and position aside.

Fig 15: Removing Bolts And Removing Parking Brake Cable Bracket
Courtesy of FORD MOTOR CO.

NOTE: The crossmember is a press fit in the crossmember pocket, it may be necessary to pry the crossmember out of the crossmember pocket. Be careful not to damage the crossmember. Only the RH side of the crossmember will need to be lowered in order to gain access to the rear extension housing.

Fig 16: Lowering RH Side Of Crossmember

G01608293

Courtesy of FORD MOTOR CO.

Lower the RH side of the crossmember.
Remove the rear transmission insulator bolts.

Fig 17: Removing Rear Transmission Insulator Bolts
Courtesy of FORD MOTOR CO.
Remove the LH and RH catalyst monitor connector retainers.

Fig 18: Removing LH And RH Catalyst Monitor Connector Retainers
Courtesy of FORD MOTOR CO.
Remove the rear extension housing bolts and the housing.

Fig 19: Removing Rear Extension Housing Bolts And Housing
Courtesy of FORD MOTOR CO.
Remove the extension housing gasket.

Fig 20: Removing Extension Housing Gasket
Courtesy of FORD MOTOR CO.