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Extension Housing Gasket: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 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.

    ALL VEHICLES 

    NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.
    Fig 1: Installing Extension Housing Gasket
    G03381008Courtesy of FORD MOTOR CO.
  1. Install the new extension housing gasket.

    VEHICLES NOT EQUIPPED WITH A FIXED FLANGE 

  2. Install the extension housing bolts.
    Fig 2: Installing Extension Housing Bolts
    G03381009Courtesy of FORD MOTOR CO.

    3. VEHICLES EQUIPPED WITH A FIXED FLANGE 

  3. Install the extension housing bolts.
    Fig 3: Installing Extension Housing Bolts
    G03381010Courtesy of FORD MOTOR CO.
  4. Using the special tool, install a new output shaft retaining nut.
    Fig 4: Installing Output Shaft Retaining Nut Using Special Tool
    G03381011Courtesy of FORD MOTOR CO.
  5. Install the output shaft flange.
    1. Install the output shaft flange.
    2. Install a new bolt.
      Fig 5: Installing Output Shaft Flange And Bolt
      G03381012Courtesy of FORD MOTOR CO.

    6. ALL VEHICLES 

  6. Connect the output shaft speed (OSS) sensor.
    Fig 6: Connecting Output Shaft Speed (OSS) Sensor
    G03381013Courtesy of FORD MOTOR CO.
  7. Install the rear transmission support insulator.
    1. Install the rear transmission support insulator.
    2. Lower the transmission onto the transmission support insulator.
      Fig 7: Installing Rear Transmission Support Insulator
      G03381014Courtesy of FORD MOTOR CO.
  8. Install the transmission insulator bolts and nuts.
    Fig 8: Installing Transmission Insulator Bolts And Nuts
    G03381015Courtesy of FORD MOTOR CO.
  9. Install the driveshaft. For additional information, refer to DRIVESHAFT .
  10. Start the engine. Move the transmission range selector lever through all the gear ranges, checking for engagements.
  11. 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).
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