Extension Housing: Service and Repair

Special Tools:

Removal

Note: 4x2 shown, 4x4 similar.

All Applications

1. Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicle's battery has been disconnected for any type of service or repair the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Manual (PCM) relearns all the parameters from the driving conditions. There is no set time frame for this process. If a concern is present during downshifts or converter clutch apply, it is not the fault of the shift strategy and will require diagnosis as outlined in the workshop manual.
The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this is a temporary condition and will eventually return to normal operating condition.

Disconnect the battery ground cable.
2. Raise the vehicle on a hoist.

4x4 Applications
3. Remove the transfer case.

All Applications
4. Remove the driveshaft.





5. Remove the transmission insulator to crossmember support nuts.





6. Install the High Lift Transmission Jack with the E40D Transmission Jack Adapter to the transmission.





7. CAUTION: Be sure not to raise the back of the transmission too high. If it makes contact with the underbody damage to the TSS and OSS sensors will occur.

Remove the rear transmission mount.
1 Raise the transmission up off the rear crossmember support.
2 Remove the bolts.
3 Remove the rear transmission mount.





8. Remove the transmission extension housing.
9. Remove and discard the extension housing gasket.

Installation
All Applications





1. CAUTION: The extension must have a shoulder or a boss cast in it to hold the orifice lube plug in the back of the case. If the wrong extension housing is used the plug may become loose and/or fall out and cause transmission damage.

Note: Lightly lubricate the gasket with petroleum jelly to hold it in place during assembly.

Install the new extension housing gasket.
1 Verify that the extension has a shoulder cast in it.
2 Install the new extension housing gasket.





2. Install the extension housing bolts.





3. CAUTION: Be sure not to raise the back of the transmission too high. If it makes contact with the underbody, damage to the TSS and OSS sensors will occur.

Install the rear transmission mount.
1 Raise the transmission up.
2 Install the rear transmission mount.
3 Install the bolts.





4. Lower the transmission on to the rear crossmember support.





5. Install the transmission insulator and nuts.





6. Remove the High Lift Transmission Jack with the E4OD Transmission Jack Adapter or equivalent to the transmission.

4x4 Applications
7. Install the transfer case.

All Applications
8. Install the driveshaft.
9. Lower the vehicle.
10. Reconnect the battery ground cable.
11. Check fluid level, fill with Motorcraft MERCON V Multipurpose (ATF) Transmission Fluid XT-5-QM or equivalent Meeting Ford specification MERCON.
12. Check for proper operation.