Extension Housing: Assembly

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: A new extension housing will not have a magnet. A new magnet must be installed.

Apply adhesive to the magnet and install.
- Only apply adhesive to the housing side of the magnet.
  
  Fig 1: Inspecting Magnet
  Courtesy of FORD MOTOR CO.
Using the Shift Rail Needle Bearing Installer with the Handle, install a new shift rail bearing.
- Using a Heat Gun, heat the bearing area of the housing to ease installation.
  
  Fig 2: Installing Shift Rail Bearing
  Courtesy of FORD MOTOR CO.
Using the Countershaft Rear Bearing Installer and the Handle, install a new countershaft bearing.
- Using a Heat Gun, heat the bearing area of the housing to ease installation.
  
  Fig 3: Installing Countershaft Bearing
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the hole in the shaft aligns with the hole in the extension housing.

NOTE: The oil grooves on the gear face the output side of the extension housing.

Fig 4: Locating Reverse Idler Shaft, Reverse Idler Gear Bearings And Reverse Idler Gear

Courtesy of FORD MOTOR CO.

Install the reverse idler shaft, reverse idler gear bearings and reverse idler gear.
Install the reverse idler shaft support.
- The ribs on the reverse idler shaft support face upward.
  
  Fig 5: Locating Reverse Idler Shaft Support
  Courtesy of FORD MOTOR CO.
Install the idler shaft bolt with a new seal.
- Tighten to 23 Nm (17 lb-ft).
  
  Fig 6: Locating Idler Shaft Bolt With Seal
  Courtesy of FORD MOTOR CO.
Install the reverse lamp switch with a new seal.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 7: Locating Reverse Lamp Switch With Seal
  Courtesy of FORD MOTOR CO.
Install the new output oil seal after the bearing preload is completed during transmission assembly.