Extension Housing Gasket: Removal

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

With the vehicle in PARK, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Four-Wheel Drive (4WD) vehicles
Remove the transfer case. For additional information, refer to TRANSFER CASE .
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.

Remove and discard the 4 driveshaft-to-transmission flange bolts. Disconnect the driveshaft from the transmission.
- Using mechanic's wire, support the driveshaft.
  
  Fig 1: Locating Driveshaft Mechanic's Wire
  Courtesy of FORD MOTOR CO.
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.

Remove the transmission support crossmember. For additional information, refer to FULL FRAME & BODY MOUNTING .
Remove the transmission insulator from the extension housing.
- Discard the bolts.
  
  Fig 3: Locating Transmission Insulator Bolts
  Courtesy of FORD MOTOR CO.
Disconnect the Output Shaft Speed (OSS) sensor.

Fig 4: Locating Output Shaft Speed (OSS) Sensor Connector
Courtesy of FORD MOTOR CO.
Using the Output Shaft Locknut Socket, remove and discard the output shaft retaining nut.

Fig 5: Removing\Installing Output Shaft Nut Using Output Shaft Locknut Socket
Courtesy of FORD MOTOR CO.
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.
Remove and discard the extension housing gasket.

Fig 7: Locating Extension Housing Gasket
Courtesy of FORD MOTOR CO.