Extension Housing: Service and Repair

Special Tools:

Removal
1. If equipped, turn the air suspension switch off.
2. Disconnect the battery ground cable.
3. Raise and support the vehicle.
4. On 4WD vehicles, remove the transfer case.
5. Drain the transmission fluid.





6. Note: To maintain initial driveshaft balance, mark the driveshaft centering socket yoke and rear axle universal joint flange so they may be installed in their original positions.

Mark the driveshaft centering socket yoke and rear axle universal joint flange.





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





8. Use the (A) Hi-Lift Jack to support the (B) transmission.
- Secure the (B) transmission with the (C) strap.





9. Remove the nuts.





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





11. Remove the (RH) transmission mount bolt.
1. Remove the bolt.
2. Reposition the exhaust mounting bracket.
12. Lower the transmission to access extension housing bolts.





13. Use the Seal Remover to remove the extension housing seal.





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

Installation

1. Note: The extension housing must be installed within four minutes after applying silicone.

Apply a small bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification ESB-M4G92-A to the surface of the case.





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





3. Use Extension Housing Seal Replacer to install the extension housing seal.
4. Raise and position the transmission.





5. Install the (RH) transmission mount bolt.
1. Position the exhaust bracket.
2. Install the bolt.





6. install the crossmember.
1. Position the crossmember.
2. Install the six bolts and nuts (three each side).
7. Remove the Hi-Lift Jack.





8. Install the nuts.





9. Note: To maintain initial driveshaft balance, align marks on the rear driveshaft centering socket yoke and rear axle universal joint flange made during removal.

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





10. Fill the (A) transmission with MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX or DDX or equivalent meeting Ford MERCON specification until it reaches the bottom of the (B) fill port and install the (C) case plug.
11. Lower the vehicle.
12. Connect the battery ground cable.
13. If equipped with air suspension, reactivate the system by turning on the air suspension switch.