Extension Housing: Assembly

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: A new extension housing will not have a magnet. A new magnet must be installed.

Apply adhesive to the magnet and install.
- Only apply adhesive to the housing side of the magnet.
  
  Fig 1: Installing Magnet
  Courtesy of FORD MOTOR CO.
Using the special tools, install a new shift rail bearing.
- Using a Heat Gun, heat the bearing area of the housing to ease installation.
  
  Fig 2: Installing Shift Rail Bearing
  Courtesy of FORD MOTOR CO.
Using the special tool, install a new countershaft bearing.
- Using a Heat Gun, heat the bearing area of the housing to ease installation.
  
  Fig 3: Installing Countershaft Bearing
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the hole in the shaft aligns with the hole in the extension housing.

NOTE: The oil grooves on the gear, face the output side of the extension housing.

Fig 4: Installing Reverse Idler Shaft, Reverse Idler Gear Bearings And Reverse Idler Gear

Courtesy of FORD MOTOR CO.

Install the reverse idler shaft, reverse idler gear bearings and reverse idler gear.
Install the reverse idler shaft support.
- The ribs on the reverse idler shaft support face upward.
  
  Fig 5: Installing Reverse Idler Shaft Support
  Courtesy of FORD MOTOR CO.
Install the reverse idler shaft bolt with a new seal.

Fig 6: Installing Reverse Idler Shaft Bolt With Seal
Courtesy of FORD MOTOR CO.
Install the reverse lamp switch with a new seal.

Fig 7: Installing Reverse Lamp Switch With Seal
Courtesy of FORD MOTOR CO.
Install the new output oil seal after the bearing preload is completed during transmission assembly.