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

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: 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.

Install the new extension housing gasket.
Install the extension housing-to-case bolts.
- Tighten to 47 Nm (35 lb-ft).
  
  Fig 2: Locating Extension Housing Bolts
  Courtesy of FORD MOTOR CO.
Connect the OSS sensor.

Fig 3: Locating Output Shaft Speed (OSS) Sensor Connector
Courtesy of FORD MOTOR CO.
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.
Install the transmission insulator and lower the transmission onto the crossmember.

Fig 5: 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.

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 6: Locating Transmission Insulator Studs
  Courtesy of FORD MOTOR CO.
Install the transfer case. For additional information, refer to TRANSFER CASE .
Start the engine. Move the selector lever through all the gear ranges, checking for engagements.
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 transmission fluid is needed, add transmission 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 transmission fluid level indicator).