Extension Housing Gasket - Rear Wheel Drive (RWD): 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.

All vehicles

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.

Vehicles not equipped with a fixed flange

Install the extension housing bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 2: Locating Extension Housing Bolts (Vehicles Not Equipped With A Fixed Flange)
  Courtesy of FORD MOTOR CO.

Vehicles equipped with a fixed flange

Install the extension housing bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 3: Locating Transmission Extension Housing Bolts
  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 output shaft flange and a new bolt.
- Tighten to 135 Nm (100 lb-ft).
  
  Fig 5: Locating Output Shaft Flange Bolt
  Courtesy of FORD MOTOR CO.

All vehicles

Connect the OSS sensor.

Fig 6: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the rear transmission mount and lower the transmission onto the crossmember.

Fig 7: Locating Rear Transmission Mount
Courtesy of FORD MOTOR CO.
Install the transmission insulator bolts and nuts.
- Tighten bolts to 94 Nm (69 lb-ft).
- Tighten nuts to 103 Nm (76 lb-ft).
  
  Fig 8: Locating Transmission Insulator Bolts
  Courtesy of FORD MOTOR CO.
Install the driveshaft. For additional information, refer to DRIVESHAFT .
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).