Extension Housing: Disassembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: To aid installation, index-mark the bolt hole position on the reverse idler shaft.

Fig 1: Removing Seal

Courtesy of FORD MOTOR CO.

Remove the bolt and seal. Discard the seal.
Remove the reverse idler shaft support.

Fig 2: Removing Reverse Idler Shaft Support
Courtesy of FORD MOTOR CO.
Remove the reverse idler gear.

Fig 3: Removing Reverse Idler Gear
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Remove the reverse idler gear bearing.

Fig 4: Removing Reverse Idler Gear Bearing
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Remove the reverse idler shaft.

Fig 5: Removing Reverse Idler Shaft
Courtesy of FORD MOTOR CO.

NOTE: Inspect the countershaft front bearing for wear or damage before removing.

Fig 6: Removing Countershaft Front Bearing

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Using the special tools, remove and discard the countershaft front bearing.

NOTE: Inspect the bearing for wear or damage before removing.

Fig 7: Removing Shift Rail Bearing

Courtesy of FORD MOTOR CO.

Using the special tools, remove and discard the shift rail bearing.
Remove the reverse lamp switch and seal. Discard the seal.

Fig 8: Removing Reverse Lamp Switch And Seal
Courtesy of FORD MOTOR CO.
Remove and discard the output oil seal.

Fig 9: Removing Output Oil Seal
Courtesy of FORD MOTOR CO.
Inspect the magnet. Make sure it is securely attached in the extension housing.

Fig 10: Inspecting Magnet
Courtesy of FORD MOTOR CO.