Seals and Gaskets: Service and Repair

NOTE: MERCON Automatic Transmission Fluid is being replaced by MERCON V as a service fluid.

Special Tools:

Special Tool:

Special Tools:

Removal
1. NOTE: 4x2 shown, 4x4 similar.

Raise the vehicle on a hoist.
2. Remove the driveshaft.





3. With a suitable drain pan properly positioned, remove the (A) extension housing seal, using the (B) Seal Remover and the (C) Impact Slide Hammer.





4. CAUTION: Do not damage any machined surfaces. Damage may cause the new seal to leak.

Using the (A) Extension Housing Bushing Remover, remove the (B) extension housing bushing.

Installation





1. CAUTION: Prior to installing the extension housing bushing, inspect the extension housing counterbore for burrs. If necessary, remove the burrs with an oil stone or damage to new bushing may occur.

Align the extension housing bushing in the extension housing so that the slots are in the 2 o'clock and 7 o'clock positions.





2. NOTE: The extension housing bushing is model-dependent. Refer to the parts catalog for the correct parts.

Using the (A) Extension Housing Bushing Replacer, install the (B) extension housing bushing.





3. Align the (A) extension housing seal in the extension housing, with the (B) drain hole positioned downward. The seal is model-dependent; refer to the parts catalog for the correct parts.





4. Using the (A) Extension Housing Seal Replacer, seat the extension housing seal into the (B) extension housing.
5. Install the driveshaft.
6. Remove the supports and lower the vehicle.
7. Fill the transmission to the specified level with Motorcraft MERCON or MERCON V Automatic Transmission Fluid or equivalent meeting FORD specification.