Extension Housing Gasket: Installation

All vehicles 

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.
Fig 1: Locating Extension Housing Gasket
Courtesy of FORD MOTOR CO.
1. Install a new extension housing gasket.
2. Install the extension housing and the transmission extension housing-to-case bolts.
   • Tighten to 47 Nm (35 lb-ft).
   Fig 2: Locating Extension Housing-To-Case Bolts

   Courtesy of FORD MOTOR CO.
3. Inspect the new output shaft nut O-ring for cuts. If cut, install a new output shaft nut.
   Fig 3: Locating Output Shaft Nut O-Ring

   Courtesy of FORD MOTOR CO.
4. Using the Output Shaft Locknut Socket, install a new output shaft retaining nut.
   • Tighten to 200 Nm (148 lb-ft).
   Fig 4: Remove/Install Output Shaft Retaining Nut Using The Output Shaft Locknut Socket

   Courtesy of FORD MOTOR CO.
5. Connect the OSS  sensor.
   Fig 5: Locating Output Shaft Speed (OSS) Sensor Connector

   Courtesy of FORD MOTOR CO.
6. If required, install new transmission insulator studs.
   • Tighten to 75 Nm (55 lb-ft).
7. Install the transmission insulator and the new transmission insulator-to-extension housing bolts.
   • Tighten to 103 Nm (76 lb-ft).
   Fig 6: Locating Transmission Insulator-To-Extension Housing Bolts

   Courtesy of FORD MOTOR CO.
8. Install the transmission support crossmember. For additional information, refer to FULL FRAME AND BODY MOUNTING article.

   RWD  vehicles

9. Install the output shaft flange and a new output shaft flange bolt.
   • Tighten to 130 Nm (96 lb-ft).
   Fig 7: Locating Output Shaft Flange And Bolt

   Courtesy of FORD MOTOR CO.
NOTE: Align index marks made during removal.
NOTE: Install new bolts and retainers.
Fig 8: Locating Driveshaft-To-Transmission Flange Index-Mark
Courtesy of FORD MOTOR CO.
10. Install the 4 new driveshaft-to-transmission flange bolts.
    • Tighten to 100 Nm (74 lb-ft).

    4WD  vehicles

11. Install the transfer case. For additional information, refer to TRANSFER CASE article.

    All vehicles 

12. Start the engine. Move the selector lever through all the gear ranges, checking for engagements.
NOTE: The use of any other transmission fluid than specified can result in the transmission failing to operate in a normal manner or transmission failure.
13. Using the scan tool with the engine running, check and make sure the transmission is at normal operating temperature 66-77°C (150-170°F). Check and adjust the transmission fluid level and check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5 pt) until the correct level is achieved.