Extension Housing: Service and Repair

Special Tools:

Removal

Note: The 4x2 application is shown, the 4x4 application is similar

All vehicles
1. Raise the vehicle on a hoist.
Excursion 7.3L diesel





2. Remove the belly pan.
1. Remove the six retaining bolts.
2. Remove the belly pan.
4x4 vehicles
3. Remove the transfer case.
All vehicles
4. Remove the driveshaft.





5. Remove the transmission insulator to crossmember support nuts.





6. Attach 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 bolts and the transmission extension housing.
9. Remove and discard the extension housing gasket.

Installation
All vehicles

1. Note:
- 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.
- 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 Transmission Jack Adapter or equivalent from the transmission.
7. Install the driveshaft.
4x4 vehicles
8. Install the transfer case.
Excursion 7.3L diesel





9. Install the belly pan.
1. Install the belly pan.
2. Install the six retaining bolts.
All vehicles
10. Lower the vehicle.
11. Check fluid level, fill with MERCON V(R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON V(R).
12. Check for correct operation.