Extension Housing: Assembly

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

NOTE: A new extension housing will not have a magnet. A new magnet must be installed.

Apply adhesive to the magnet and install.
- Only apply adhesive to the housing side of the magnet.
  
  Fig 1: Applying Adhesive To Magnet
  Courtesy of FORD MOTOR CO.
Using the special tools, install a new shift rail bearing.
- Using a Heat Gun, heat the bearing area of the housing to ease installation.
  
  Fig 2: Installing New Shift Rail Bearing
  Courtesy of FORD MOTOR CO.
Using the special tool, install a new countershaft bearing.
- Using a Heat Gun, heat the bearing area of the housing to ease installation.
  
  Fig 3: Installing Countershaft Bearing
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the hole in the shaft aligns with the hole in the extension housing.

NOTE: The oil grooves on the gear, face the output side of the extension housing.

Fig 4: Installing Reverse Idler Shaft

Courtesy of FORD MOTOR CO.

Install the reverse idler shaft, reverse idler gear bearings and reverse idler gear.
Install the reverse idler shaft support.
- The ribs on the reverse idler shaft support face upward.
  
  Fig 5: Installing Reverse Idler Shaft Support
  Courtesy of FORD MOTOR CO.
Install the reverse idler shaft bolt with a new seal.

Fig 6: Installing Reverse Idler Shaft Bolt With A New Seal
Courtesy of FORD MOTOR CO.
Install the reverse lamp switch with a new seal.

Fig 7: Installing Reverse Lamp Switch With A New Seal
Courtesy of FORD MOTOR CO.
Install the new output oil seal after the bearing preload is completed during transmission assembly.