Extension Housing: Disassembly

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: To aid installation, index-mark the bolt hole position on the reverse idler shaft.

Remove the bolt and seal. Discard the seal.

Fig 1: Reverse Idler Shaft Bolt

Courtesy of FORD MOTOR CO.

Remove the reverse idler shaft support.

Fig 2: Reverse Idler Shaft Support

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Remove the reverse idler gear.
- Inspect the gear for wear or damage.
- Check the teeth for chips or burrs.
- Install a new gear as necessary.

Fig 3: Reverse Idler Gear

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Remove the reverse idler gear bearing.
- Inspect the bearing for wear or damage.
- Install a new bearing as necessary.

Fig 4: Reverse Idler Gear Bearing

Courtesy of FORD MOTOR CO.

Remove the reverse idler shaft.

Fig 5: Reverse Idler Shaft

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NOTE: Inspect the countershaft front bearing for wear or damage before removing.

Using the special tools, remove and discard the countershaft front bearing.

Fig 6: Removing Countershaft Front Bearing

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NOTE: Inspect the bearing for wear or damage before removing.

Using the special tools, remove and discard the shift rail bearing.

Fig 7: Removing Shift Rail Bearing

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Remove the reverse lamp switch and seal. Discard the seal.

Fig 8: Reverse Lamp Switch

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Remove and discard the output oil seal.

Fig 9: Output Oil Seal

Courtesy of FORD MOTOR CO.

Inspect the magnet. Make sure it is securely attached in the extension housing.

Fig 10: Extension Housing Magnet

Courtesy of FORD MOTOR CO.