Extension Housing Gasket: Removal

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: If equipped with fire suppression system, depower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .

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

NOTE: The output shaft and driveshaft are a balanced assembly.

Fig 1: Identifying Driveshaft Flange-To-Pinion Flange Alignment Marks

Courtesy of FORD MOTOR CO.

Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly.
Remove the 4 driveshaft bolts.

Fig 2: Identifying Driveshaft Bolts
Courtesy of FORD MOTOR CO.
Slide the drive shaft back enough to index-mark the driveshaft, output shaft and the extension housing. Separate the driveshaft from the transmission.

Fig 3: Locating Driveshaft, Output Shaft And Extension Housing
Courtesy of FORD MOTOR CO.
Remove the rear transmission insulator nuts.

Fig 4: Locating Rear Transmission Insulator Nuts
Courtesy of FORD MOTOR CO.
Disconnect the RH heated oxygen sensor (HO2S) sensor connector.

Fig 5: Identifying RH Heated Oxygen Sensor (HO2S) Sensor Connector
Courtesy of FORD MOTOR CO.
Disconnect the RH catalyst monitor connector.

Fig 6: RH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
Remove the bolts from the RH exhaust flange.

Fig 7: Identifying RH Exhaust Flange Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the RH catalytic converter.

Fig 8: Identifying RH Catalytic Converter Bolts
Courtesy of FORD MOTOR CO.
Disconnect the LH HO2S connector.

Fig 9: Identifying LH HO2S Connector
Courtesy of FORD MOTOR CO.
Disconnect the LH catalyst monitor connector.

Fig 10: LH Catalyst Monitor Connector
Courtesy of FORD MOTOR CO.
Remove the bolts from the LH exhaust flange.

Fig 11: Removing Bolts From LH Exhaust Flange
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the LH catalytic converter.

Fig 12: Removing Bolts And LH Catalytic Converter
Courtesy of FORD MOTOR CO.
Install a suitable transmission jack.
Remove the RH side crossmember bolts.

Fig 13: Removing RH Side Crossmember Bolts
Courtesy of FORD MOTOR CO.
Disconnect the LH side crossmember.
1. Loosen but do not remove the LH side crossmember bolts.
2. Remove the LH side crossmember bolt.
  
  Fig 14: Removing LH Side Crossmember Bolt
  Courtesy of FORD MOTOR CO.
Remove the bolts and remove the parking brake cable bracket and position aside.

Fig 15: Removing Parking Brake Cable Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: The crossmember is a press fit in the crossmember pocket, it may be necessary to pry the crossmember out of the crossmember pocket. Be careful not to damage the crossmember. Only the RH side of the crossmember will need to be lowered in order to gain access to the rear extension housing.

Fig 16: Locating Lower RH Side Of Crossmember

Courtesy of FORD MOTOR CO.

Lower the RH side of the crossmember.
Remove the rear transmission insulator bolts.

Fig 17: Removing Rear Transmission Insulator Bolts
Courtesy of FORD MOTOR CO.
Remove the LH and RH catalyst monitor connector retainers.

Fig 18: Removing LH And RH Catalyst Monitor Connector Retainers
Courtesy of FORD MOTOR CO.
Remove the rear extension housing bolts and the housing.

Fig 19: Removing Rear Extension Housing Bolts And Housing
Courtesy of FORD MOTOR CO.
Remove the extension housing gasket.

Fig 20: Removing Extension Housing Gasket
Courtesy of FORD MOTOR CO.