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Extension Housing Gasket: Installation

WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install a new extension housing gasket.
    2. Fig 1: Rear Extension Housing Gasket
    GF0014059Courtesy of FORD MOTOR CO.
  2. Install the extension housing and the bolts.
    • Tighten to 28 Nm (21 lb-ft).
    3. Fig 2: Rear Extension Housing Bolts
    GF0014060Courtesy of FORD MOTOR CO.
  3. Install the LH and RH catalyst monitor connector retainers.
    4. Fig 3: LH And RH Catalyst Monitor Connector Retainers
    GF0014057Courtesy of FORD MOTOR CO.
  4. Install the rear transmission insulator and bolts.
    • Tighten to 90 Nm (66 lb-ft).
    5. Fig 4: Rear Transmission Insulator Bolts
    GF0014061Courtesy of FORD MOTOR CO.
  5. Position the RH crossmember and install the bolts.
    • Tighten to 70 Nm (52 lb-ft).
    6. Fig 5: RH Side Crossmember Bolts
    GF0014062Courtesy of FORD MOTOR CO.
  6. Install the LH side crossmember bolt.
    • Tighten to 70 Nm (52 lb-ft).
    7. Fig 6: LH Side Crossmember Bolts
    GF0014063Courtesy of FORD MOTOR CO.
  7. Install the parking brake cable bracket.
    • Tighten to 55 Nm (41 lb-ft).
    8. Fig 7: Parking Brake Cable Bracket Bolts
    GF0014064Courtesy of FORD MOTOR CO.
  8. Lower the transmission onto the crossmember and install the rear transmission insulator nuts.
    • Tighten to 30 Nm (22 lb-ft).
    9. Fig 8: Rear Transmission Insulator Nuts
    GF0014065Courtesy of FORD MOTOR CO.
  9. Remove the transmission jack.
  10. Install a new gasket and position the RH catalytic converter assembly in place and loosely install the bolts. Do not tighten the bolts at this time.
    11. Fig 9: RH Catalytic Converter Bolts
    GF0014049Courtesy of FORD MOTOR CO.
  11. Install the RH exhaust flange nuts.
    • Tighten to 48 Nm (35 lb-ft).
    12. Fig 10: RH Exhaust Flange Bolts
    GF0014066Courtesy of FORD MOTOR CO.
  12. Tighten the RH exhaust bolts.
    • Tighten to 40 Nm (30 lb-ft).
    13. Fig 11: RH Catalytic Converter Bolts
    GF0014049Courtesy of FORD MOTOR CO.
  13. Connect the RH HO2S connector.
    14. Fig 12: RH Heated Oxygen Sensor (HO2S) Sensor Connector
    GF0014047Courtesy of FORD MOTOR CO.
  14. Connect the RH catalyst monitor connector.
    15. Fig 13: RH Catalyst Monitor Connector
    G04016678Courtesy of FORD MOTOR CO.
  15. Install a new gasket and position the LH catalytic converter assembly in place and loosely install the bolts. Do not tighten the bolts at this time.
    16. Fig 14: LH Catalytic Converter Bolts
    GF0014051Courtesy of FORD MOTOR CO.
  16. Install the LH exhaust flange nuts.
    • Tighten to 48 Nm (35 lb-ft).
    17. Fig 15: LH Exhaust Flange Bolts
    GF0014067Courtesy of FORD MOTOR CO.
  17. Tighten the LH exhaust bolts.
    • Tighten to 40 Nm (30 lb-ft).
    18. Fig 16: LH Catalytic Converter Bolts
    GF0014051Courtesy of FORD MOTOR CO.
  18. Connect the LH HO2S sensor connector.
    19. Fig 17: Identifying LH HO2S Connector
    G04584303Courtesy of FORD MOTOR CO.
  19. Connect the LH catalyst monitor connector.
    20. Fig 18: LH Catalyst Monitor Connector
    G04584304Courtesy of FORD MOTOR CO.
    NOTE: The output shaft and the driveshaft are a balanced assembly.
  20. Install the driveshaft.
    • Align the index marks and position the driveshaft on the transmission.
    • Install the driveshaft.
    21. Fig 19: Positioning Driveshaft On Transmission
    GF0003502Courtesy of FORD MOTOR CO.
    NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original position that was marked during removal.
  21. Install the 4 retaining bolts.
    • Tighten to 103 Nm (76 lb-ft).
    22. Fig 20: Identifying Driveshaft Bolts
    G04016647Courtesy of FORD MOTOR CO.
  22. Lower the vehicle.
    23. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
  23. Check the level of the transmission fluid. Add clean automatic transmission fluid as necessary.
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