Extension Housing Gasket - Four Wheel Drive (4WD): Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.

Fig 1: Locating Extension Housing Gasket

Courtesy of FORD MOTOR CO.

Install the new extension housing gasket.
Install the extension housing bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 2: Locating Transmission Extension Housing Bolts
  Courtesy of FORD MOTOR CO.
Connect the OSS sensor.

Fig 3: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Using the special tool, install a new output shaft retaining nut.
- Tighten to 200 Nm (148 lb-ft).
  
  Fig 4: Identifying Output Shaft With Special Tool
  Courtesy of FORD MOTOR CO.
Install the transfer case. For additional information, refer to TRANSFER CASE .
Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
With the vehicle in NEUTRAL, engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).