Extension Housing: Disassembly

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

Fig 1: Locating Reverse Idler Shaft Bolt And Seal

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Remove the reverse idler shaft bolt and seal. Discard the seal.
Remove the reverse idler shaft support.

Fig 2: Identifying 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: Removing 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: Removing Reverse Idler Gear Bearing
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Remove the reverse idler shaft.

Fig 5: Removing Reverse Idler Shaft
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NOTE: Inspect the countershaft front bearing for wear or damage before removing.

Fig 6: Removing Countershaft Front Bearing

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Using the Universal Puller Set, remove and discard the countershaft front bearing.

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

Fig 7: Removing Shift Rail Bearing

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Using the Universal Puller Set, remove and discard the shift rail bearing.
Remove the reverse lamp switch and seal. Discard the seal.

Fig 8: Locating Reverse Lamp Switch And Seal
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Remove and discard the output oil seal.

Fig 9: Removing Output Oil Seal
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Inspect the magnet. Make sure it is securely attached in the extension housing.

Fig 10: Inspecting Magnet
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