Extension Housing Gasket - Four Wheel Drive (4WD): Removal

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The transmission insulator studs may come out of the insulator while removing the nuts. Install new insulator studs if the studs come out of the insulator.

Remove the transfer case. For additional information, refer to TRANSFER CASE .
Using the Output Shaft Locknut Socket, remove and discard the output shaft retaining nut.

Fig 1: Removing Output Shaft Retaining Nut
Courtesy of FORD MOTOR CO.
Remove the transmission insulator-to-crossmember nuts.

Fig 2: Locating Rear Transmission Insulator And Retainer Nuts
Courtesy of FORD MOTOR CO.
Install a suitable transmission jack.
Remove the transmission insulator-to-extension housing bolts.

Fig 3: Locating Transmission Insulator And Retainer Bolts
Courtesy of FORD MOTOR CO.
Raise the transmission upward, off the transmission insulator and remove the transmission insulator.

Fig 4: Locating Transmission Upward
Courtesy of FORD MOTOR CO.
Disconnect the Output Shaft Speed (OSS) sensor.

Fig 5: Locating Output Shaft Speed (OSS) Sensor Connector
Courtesy of FORD MOTOR CO.
Remove the extension housing-to-case bolts and the extension housing.

Fig 6: Locating Extension Housing Bolts
Courtesy of FORD MOTOR CO.
Remove and discard the extension housing gasket.

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