Extension Housing Gasket - 4X4: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 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: Installing Extension Housing Gasket

Courtesy of FORD MOTOR CO.

Install the new extension housing gasket.
Install the extension housing bolts.

Fig 2: Installing Extension Housing Bolts
Courtesy of FORD MOTOR CO.
Connect the output shaft speed (OSS) sensor.

Fig 3: Connecting Output Shaft Speed Sensor
Courtesy of FORD MOTOR CO.
Using the special tool, install a new output shaft retaining nut.

Fig 4: Installing Output Shaft Retaining Nut
Courtesy of FORD MOTOR CO.
Install the transfer case. 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).