Extension Housing Gasket: Removal

All vehicles 

1. With the vehicle in PARK, position it on a hoist. For additional information, refer to JACKING & LIFTING article.

   Four-Wheel Drive (4WD) vehicles 

2. Remove the transfer case. For additional information, refer to TRANSFER CASE article.

   Rear Wheel Drive (RWD) vehicles 

NOTE: It may be necessary to tap the driveshaft yoke with a plastic or rubber soft-faced hammer if a pry area is not present on the driveshaft side.
NOTE: Index-mark the driveshaft flanges.
Fig 1: Locating Driveshaft-To-Transmission Flange Index-Mark
Courtesy of FORD MOTOR CO.
3. Remove and discard the 4 driveshaft-to-transmission flange bolts. Disconnect the driveshaft from the transmission.
   • Using mechanic's wire, support the driveshaft.
4. Remove the output shaft flange.
   1. Remove and discard the output shaft flange bolt.
   2. Remove the output shaft flange.
   Fig 2: Identifying Output Shaft Flange And Bolt

   Courtesy of FORD MOTOR CO.

   All vehicles 

NOTE: The transmission insulator studs may come out of the insulator while removing the insulator-to-crossmember nuts. Install new transmission insulator studs if the studs come out.
5. Remove the transmission support crossmember. For additional information, refer to FULL FRAME AND BODY MOUNTING article.
6. Remove the transmission insulator from the extension housing.
   • Discard the bolts.
   Fig 3: Locating Transmission Insulator-To-Extension Housing Bolts

   Courtesy of FORD MOTOR CO.
7. Disconnect the Output Shaft Speed (OSS) sensor.
   Fig 4: Locating Output Shaft Speed (OSS) Sensor Connector

   Courtesy of FORD MOTOR CO.
8. Using the Output Shaft Locknut Socket, remove and discard the output shaft retaining nut.
   Fig 5: Remove/Install Output Shaft Retaining Nut Using The Output Shaft Locknut Socket

   Courtesy of FORD MOTOR CO.
9. Remove the extension housing-to-case bolts and the transmission extension housing.
   Fig 6: Locating Extension Housing-To-Case Bolts

   Courtesy of FORD MOTOR CO.
10. Remove and discard the extension housing gasket.
    Fig 7: Locating Extension Housing Gasket

    Courtesy of FORD MOTOR CO.