Extension Housing Gasket - Rear Wheel Drive (RWD): Installation

All vehicles 

NOTE: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.
Fig 1: Locating Extension Housing Gasket
Courtesy of FORD MOTOR CO.
1. Install the new extension housing gasket.

   Transmissions without a fixed flange 

2. Install the extension housing-to-case bolts.
   • Tighten to 47 Nm (35 lb-ft).
     Fig 2: Locating Transmissions Without Fixed Flange

     Courtesy of FORD MOTOR CO.

   Transmissions with a fixed flange 

3. Install the extension housing-to-case bolts.
   • Tighten to 47 Nm (35 lb-ft).
     Fig 3: Locating Transmissions With Fixed Flange

     Courtesy of FORD MOTOR CO.
4. Using the Output Shaft Locknut Socket, install a new output shaft retaining nut.
   • Tighten to 200 Nm (148 lb-ft).
     Fig 4: Removing Output Shaft Retaining Nut

     Courtesy of FORD MOTOR CO.
5. Install the output shaft flange and a new output shaft flange bolt.
   • Tighten to 130 Nm (96 lb-ft).
     Fig 5: Locating Output Shaft Flange And Bolt

     Courtesy of FORD MOTOR CO.

   All vehicles 

6. Connect the OSS  sensor.
   Fig 6: Locating Output Shaft Speed (OSS) Sensor Connector

   Courtesy of FORD MOTOR CO.
7. Install the transmission insulator and lower the transmission onto the crossmember.
   Fig 7: Locating Transmission Insulator And Lower Transmission Onto Crossmember

   Courtesy of FORD MOTOR CO.
NOTE: The transmission insulator studs may come out of the insulator when removing the nuts. Install new insulator studs if the studs comes out of the insulator.
8. Install the transmission insulator bolts and nuts.
   • Tighten the transmission insulator studs to 75 Nm (55 lb-ft).
   • Tighten the transmission insulator-to-extension housing bolts to 103 Nm (76 lb-ft).
   • Tighten transmission insulator-to-crossmember nuts to 115 Nm (85 lb-ft).
     Fig 8: Locating Transmission Insulator Bolts And Nuts

     Courtesy of FORD MOTOR CO.
9. Install the driveshaft. For additional information, refer to DRIVESHAFT .
10. Start the engine. Move the selector lever through all the gear ranges, checking for engagements.
11. With the vehicle in NEUTRAL, engine running and the transmission at normal operating temperature 66-77°C (150-170°F), check and adjust the transmission fluid level, and check for any leaks. If fluid is needed, add fluid in increments of 0.24L (0.5 pt) until the correct level is achieved (fluid should be in the hot range cross-hatched area of the fluid level indicator).