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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1490 (Manual Transmission - Tr6060) >> Disassembly And Assembly Of Subassemblies >> Extension Housing >> Disassembly And Assembly

Disassembly And Assembly

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the output shaft speed (OSS) bolt and the OSS sensor.
    • To install, tighten to 10 Nm (89 lb-in).
    2. Fig 1: Locating Output Shaft Speed (OSS) Bolt & OSS Sensor
    GF0001201Courtesy of FORD MOTOR CO.
  2. Remove the reverse lockout solenoid bolt and the reverse lockout solenoid.
    • To install, tighten to 18 Nm (13 lb-ft).
    3. Fig 2: Locating Reverse Lockout Solenoid Bolt & Reverse Lockout Solenoid
    GF0001202Courtesy of FORD MOTOR CO.
  3. Remove the 3 reverse idler shaft bracket bolts and the reverse idler shaft bracket.
    • To install, tighten to 30 Nm (22 lb-ft).
    4. Fig 3: Locating Reverse Idler Shaft Bracket Bolts & Reverse Idler Shaft Bracket
    GF0001203Courtesy of FORD MOTOR CO.
  4. Remove the reverse idler gear.
    5. Fig 4: Locating Reverse Idler Gear
    GF0001204Courtesy of FORD MOTOR CO.
  5. Remove the reverse idler gear needle bearing.
    • Inspect the needle bearing for wear or damage. Install a new bearing as necessary.
    6. Fig 5: Locating Reverse Idler Gear Needle Bearing
    GF0001205Courtesy of FORD MOTOR CO.
  6. Remove the reverse idler gear shaft.
    7. Fig 6: Locating Reverse Idler Gear Shaft
    GF0001206Courtesy of FORD MOTOR CO.
  7. If necessary, remove the bearing and fluid funnel assembly.
  8. Remove the countershaft bearing cup snap ring and the bearing cup.
  9. Remove and discard the extension housing seal.
    10. Fig 7: Locating Countershaft Bearing Cup Snap Ring & Bearing Cup
    GF0001207Courtesy of FORD MOTOR CO.
  10. Clean the housing with solvent and dry with compressed air. Clean and check the sealing surface for nicks or scratches. Inspect the housing for cracks.
    • If the housing is cracked, install a new housing. If the sealing surface has nicks or scratches, use a soft stone or crocus cloth to remove.
  11. Remove the snap ring. Position the extension housing with the seal facing downward. Using a brass drift, remove the output shaft bearing.
    12. Fig 8: Identifying Output Shaft Bearing
    GF0001208Courtesy of FORD MOTOR CO.
  12. To assemble, reverse the disassembly procedure.
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