Extension Housing Gasket - Excursion: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The 4x2 application is shown, the 4x4 application is similar.

All vehicles

Raise the vehicle on a hoist. Refer to Jacking & Lifting .
4x4 vehicles
Remove the transfer case. Refer to TRANSFER CASE .
All vehicles
Remove the driveshaft. Refer to DRIVESHAFT .
Remove the rear transmission mount brace nuts.

Fig 1: Removing Driveshaft
Courtesy of FORD MOTOR CO.

CAUTION: Be sure not to raise the back of the transmission too high. If it makes contact with the underbody, damage to the TSS and OSS sensors will occur.

Remove the rear transmission brace.
1. Raise the transmission to gain access to the rear transmission brace nuts.
2. Remove the transmission brace.
  
  Fig 2: Removing Transmission Brace
  Courtesy of FORD MOTOR CO.

NOTE: It will be necessary to remove the bolts from the transmission mount in order to get the transmission brace out. The transmission mount and brace must come out together.

Fig 3: Removing Mount And Brace

Courtesy of FORD MOTOR CO.

Remove the two nuts from the transmission mount and remove the mount and the brace.
Disconnect the output shaft speed (OSS) sensor.

Fig 4: Disconnecting Output Shaft Speed (OSS) Sensor
Courtesy of FORD MOTOR CO.
Lower the transmission to gain access to the bolts. Remove the bolts and the extension housing.

Fig 5: Removing Bolts And Extension Housing
Courtesy of FORD MOTOR CO.
Remove and discard the extension housing gasket.