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Extension Housing Gasket: Installation

WARNING: This page is about a different car, the 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 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.
    Fig 1: Installing New Extension Housing Gasket
    G02762096Courtesy of FORD MOTOR CO.
  1. Install the new extension housing gasket.
    • Verify that the extension has a shoulder cast in it.
    • Install the new extension housing gasket.
    2. NOTE: Make sure the fasteners are installed in their correct locations as noted during removal.
    Fig 2: Installing Extension Housing
    G02762097Courtesy of FORD MOTOR CO.
  2. Install the extension housing.
    1. Install the extension housing.
    2. Install the eight bolts.
    3. Install the stud.
    3. 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 3: Installing Transmission Insulator
    G02762098Courtesy of FORD MOTOR CO.
  3. Install the transmission insulator and retainer and the bolts.
  4. Lower the transmission on to the rear crossmember support.
    Fig 4: Identifying Lower The Transmission On To The Rear Crossmember Support
    G02762099Courtesy of FORD MOTOR CO.
  5. Install the transmission insulator and retainer-to-crossmember retaining nuts.
    Fig 5: Installing Transmission Insulator And Retainer-To-Crossmember
    G02762100Courtesy of FORD MOTOR CO.
  6. Remove the high lift transmission jack with the special tool from the transmission.
    Fig 6: Removing High Lift Transmission Jack
    G02762101Courtesy of FORD MOTOR CO.
  7. Install the transmission fluid pan-to-case retaining bolts.
    Fig 7: Installing Transmission Fluid Pan-To-Case
    G02762102Courtesy of FORD MOTOR CO.
  8. If equipped, install the transmission-mounted parking brake assembly.
  9. Install the driveshaft.
  10. Lower the vehicle.
  11. Fill the transmission to the specified level with clean automatic transmission fluid. For additional information, refer to the Fluid Capacity chart in the General Specifications  portion of this article.
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