Extension Housing: Assembly

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, 2007 Ford Cab & Chassis, and 2006 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.

Fig 1: Extension Housing Magnet

Courtesy of FORD MOTOR CO.

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 2: Installing Shift Rail Bearing

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 3: Installing Countershaft 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 4: Reverse Idler Shaft, Reverse Idler Gear Bearings & Reverse Idler Gear With Oil Grooves

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.

Install the reverse idler shaft, reverse idler gear bearings and reverse idler gear.

Fig 5: Reverse Idler Shaft Support

Courtesy of FORD MOTOR CO.

Install the reverse idler shaft support.
- The ribs on the reverse idler shaft support face upward.

Fig 6: Reverse Idler Shaft Bolt

Courtesy of FORD MOTOR CO.

Install the idler shaft bolt with a new seal.
- Tighten to 23 Nm (17 lb-ft).

Fig 7: Reverse Lamp Switch

Courtesy of FORD MOTOR CO.

Install the reverse lamp switch with a new seal.
- Tighten to 20 Nm (15 lb-ft).
Install the new output oil seal after the bearing preload is completed during transmission assembly.