Extension Housing Gasket: Removal

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.

WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in FIRE SUPPRESSION SYSTEM article. Failure to follow the instructions may result in serious personal injury.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.

NOTE: The output shaft and driveshaft are a balanced assembly.

Mark the driveshaft flange and the rear pinion flange for correct alignment during assembly.

Fig 1: Marking Driveshaft Flange And Rear Pinion Flange

Courtesy of FORD MOTOR CO.

Remove the 4 driveshaft bolts.

Fig 2: Identifying Driveshaft Bolts

Courtesy of FORD MOTOR CO.

Slide the drive shaft back enough to index-mark the driveshaft, output shaft and the extension housing. Separate the driveshaft from the transmission.

Fig 3: Marking Driveshaft, Extension Housing And Output Shaft

Courtesy of FORD MOTOR CO.

Remove the rear transmission insulator nuts.

Fig 4: Rear Transmission Insulator Nuts

Courtesy of FORD MOTOR CO.

Disconnect the RH heated oxygen sensor (HO2S) sensor connector.

Fig 5: RH Heated Oxygen Sensor (HO2S) Sensor Connector

Courtesy of FORD MOTOR CO.

Disconnect the RH catalyst monitor connector.

Fig 6: RH Catalyst Monitor Connector

Courtesy of FORD MOTOR CO.

Remove the bolts from the RH exhaust flange.

Fig 7: RH Exhaust Flange Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the RH catalytic converter.

Fig 8: RH Catalytic Converter Bolts

Courtesy of FORD MOTOR CO.

Disconnect the LH HO2S connector.

Fig 9: Identifying LH HO2S Connector

Courtesy of FORD MOTOR CO.

Disconnect the LH catalyst monitor connector.

Fig 10: LH Catalyst Monitor Connector

Courtesy of FORD MOTOR CO.

Remove the bolts from the LH exhaust flange.

Fig 11: LH Exhaust Flange Bolts

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the LH catalytic converter.

Fig 12: LH Catalytic Converter Bolts

Courtesy of FORD MOTOR CO.

Install a suitable transmission jack.
Remove the RH side crossmember bolts.

Fig 13: RH Side Crossmember Bolts

Courtesy of FORD MOTOR CO.

Disconnect the LH side crossmember.
1. Loosen but do not remove the LH side crossmember bolts.
2. Remove the LH side crossmember bolt.

Fig 14: LH Side Crossmember Bolts

Courtesy of FORD MOTOR CO.

Remove the bolts and remove the parking brake cable bracket and position aside.

Fig 15: Parking Brake Cable Bracket Bolts

Courtesy of FORD MOTOR CO.

NOTE: The crossmember is a press fit in the crossmember pocket, it may be necessary to pry the crossmember out of the crossmember pocket. Be careful not to damage the crossmember. Only the RH side of the crossmember will need to be lowered in order to gain access to the rear extension housing.