Extension Housing: Service and Repair

Special Tools:

Removal
1. Disconnect the battery ground cable.
2. If equipped, turn the air suspension switch off.
3. Raise and support the vehicle.
4. Drain the transmission fluid.





5. Remove and support the rear driveshaft.
1 Remove the bolts.
2 Remove the rear driveshaft.





6. Remove the Vehicle Speed Sensor (VSS).
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Remove the VSS.





7. Use (A) the High-Lift Jack to support the (B) transmission.
^ Secure the transmission with the (C) strap.





8. Remove the transmission mount nuts.





9. Remove the heat shield bolts (one each side).





10. Remove the crossmember.
1 Remove the bolts (three each side).
2 Remove the crossmember.





11. Remove the transmission mount.
1 Remove the bolts.
2 Remove the transmission mount.





12. Remove the exhaust pipe bracket. Remove the nuts. Remove the exhaust pipe bracket.
13. Lower the transmission to access extension housing bolts.





14. Use (A) Seal Remover to remove the (B) extension housing seal.





15. Remove the extension housing.
1 Remove the bolts.
2 Remove the extension housing.





16. Remove the speedometer drive gear.
1 Remove the speedometer gear retaining ring.
2 Remove the speedometer drive gear.

Installation





1. Install the speedometer drive gear.
1 Install the speedometer drive gear.
2 Install the speedometer gear retaining ring.

2. Note: Extension housing must he installed within four minutes after applying silicone.

Apply a small bead of silicone rubber to the surface of the extension housing.
^ Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A.





3. Install the extension housing.
1 Position the extension housing.
2 Install the bolts.





4. Use (A) Extension Housing Seal Replacer to install a new (B) extension housing seal.
5. Raise and position the transmission.





6. Install the exhaust pipe bracket.
1 Position the exhaust pipe bracket.
2 Install the nuts.





7. Install the transmission mount.
1 Position the transmission mount.
2 Install the bolts.





8. Install the crossmember.
1 Position the crossmember.
2 Install the bolts and nuts.





9. Install the heat shield bolts (one each side).
10. Remove the High-Lift Jack.





11. Install the transmission mount nuts.





12. Install the VSS.
1 Install the VSS.
2 Install the bolt.
3 Connect the electrical connector.





13. Install the rear driveshaft.
1 Position the rear driveshaft.
2 Install the bolts.





14. Fill (A) transmission with fluid until it reaches the bottom of the (B) fill port and install the (C) bolt.
^ Use Motorcraft MERCON Multipurpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent Mercon Automatic Transmission Fluid.
15. Lower the vehicle.
16. Connect the battery ground cable.
17. If equipped with air suspension, reactivate the system by turning on the air suspension switch.