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Extension Housing Gasket: Installation

WARNING: This page is about a different car, the 2002 Ford RV Cutaway, 2002 Ford Econoline, 2002 Ford E550 Super Duty, 2002 Ford E450 Super Duty, and 2002 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: The extension must have a shoulder or a boss cast in it to hold the orifice lube plug in the back of the case. If the wrong extension housing is used the plug may become loose and/or fall out and cause transmission damage.
    NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.
  1. Install the new extension housing gasket.
    • Verify that the extension has a shoulder cast in it.
    • Install the new extension housing gasket.
      Fig 1: Installing New Extension Housing Gasket
      G01962889Courtesy of FORD MOTOR CO.
    2. NOTE: Make sure the fasteners are installed in their correct locations as noted during removal.
  2. Install the extension housing.
    1. Install the extension housing.
    2. Install the eight bolts.
    3. Install the stud.
      Fig 2: Installing Extension Housing
      G01962890Courtesy of FORD MOTOR CO.
  3. Install the vehicle speed sensor (VSS).
    1. Install the VSS.
    2. Install the bolt.
    3. Connect the electrical connector.
      Fig 3: Installing VSS
      G01962891Courtesy of FORD MOTOR CO.
    4. CAUTION: Be sure not to raise the back of the transmission too high. If it makes contact with the underbody, damaged to the TSS sensor should occur.
    Fig 4: Installing Transmission Insulator And Retainer Bolts
    G01962892Courtesy of FORD MOTOR CO.
  4. Install the transmission insulator and retainer and the bolts.
  5. Lower the transmission on to the rear crossmember support.
    Fig 5: Identifying Lower Transmission On To Rear Crossmember Support
    G01962893Courtesy of FORD MOTOR CO.
  6. Install the transmission insulator and retainer-to-crossmember retaining nuts.
    Fig 6: Installing Transmission Insulator And Retainer-To-Crossmember Retaining Nuts
    G01962894Courtesy of FORD MOTOR CO.
  7. Remove the high lift transmission jack with the special tool from the transmission.
    Fig 7: Removing High Lift Transmission Jack With Special Tool From Transmission
    G01962895Courtesy of FORD MOTOR CO.
  8. Install the transmission fluid pan-to-case retaining bolts.
    Fig 8: Installing Transmission Fluid Pan-To-Case Retaining Bolts
    G01962896Courtesy of FORD MOTOR CO.
  9. If equipped, install the transmission-mounted parking brake assembly.
  10. Install the driveshaft.
  11. Lower the vehicle.
  12. Connect the battery ground cable.
  13. Fill the transmission to the specified level with clean automatic transmission fluid. For additional information, refer to the Fluid Capacity  table.
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