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Extension Housing Gasket: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 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: Identifying Extension Housing Gasket
    G03889106Courtesy of FORD MOTOR CO.
  1. Install the new extension housing gasket.

    2. Vehicles not equipped with a fixed flange 

  2. Install the extension housing bolts.
    Fig 2: Installing Extension Housing Bolts
    G03889108Courtesy of FORD MOTOR CO.

    3. Vehicles equipped with a fixed flange 

  3. Install the extension housing bolts.
    Fig 3: Extension Housing Bolts - With Torque Specification
    G03889109Courtesy of FORD MOTOR CO.
  4. Using the special tool, install a new output shaft nut.
    Fig 4: Installing A New Output Shaft Nut Using Special Tool With Torque Specification
    G03889095Courtesy of FORD MOTOR CO.
  5. Install the output shaft flange.
    1. Install the output shaft flange.
    2. Install a new bolt.
      Fig 5: Output Shaft Flange - With Torque Specification
      G03889096Courtesy of FORD MOTOR CO.

    6. All vehicles 

  6. Connect the output shaft speed (OSS) sensor.
    Fig 6: Identifying Output Shaft Speed (OSS) Sensor Electrical Connector
    G03889074Courtesy 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: Identifying Rear Transmission Mount
      G03889113Courtesy of FORD MOTOR CO.
  8. Install the transmission insulator bolts and nuts.
    Fig 8: Identifying Transmission Insulator Bolts And Nuts
    G03889114Courtesy of FORD MOTOR CO.
  9. Install the 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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