Extension Housing: Service and Repair

Special Tools:

REMOVAL
1. Disconnect the battery ground cable.

WARNING: ON VEHICLES EQUIPPED WITH AN AUXILIARY BATTERY, BOTH THE NEGATIVE AND POSITIVE BATTERY CABLES MUST BE DISCONNECTED.

WARNING: ON VEHICLES EQUIPPED WITH A 7.3L ENGINE, BOTH THE PRIMARY AND SECONDARY BATTERIES MUST BE DISCONNECTED.

2. Raise and support the vehicle.
3. Remove the driveshaft.
4. Remove the transmission-mounted parking brake assembly (if so equipped).





5. Remove the transmission insulator and retainer-to-crossmember retaining nuts.





6. Secure the (A) High lift Transmission Jack with the (B) E40D Transmission Jack Adapter to the (C) transmission.





7. Raise the transmission jack until the (A) transmission insulator and retainer studs are separated from the (B) transmission support crossmember.





8. Remove the (A) bolts and the (B) transmission insulator and retainer.





9. Disconnect the (A) harness connector and position it aside. Remove the (B) bolt and the (C) vehicle speed sensor (VSS).





10. With a suitable drain pan properly positioned, remove the 8 (A) bolts, the (B) stud and the (C) extension housing.

NOTE: Super Duty applications use a special 4x4 extension housing.

NOTE: As the fasteners are removed, note the size of each for proper location during installation.





11. Remove and discard the extension housing gasket.

INSTALLATION





1. Place the new extension housing gasket on the extension housing.

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





2. Install the (A) extension housing, the 8 (B) bolts and the (C) stud.

NOTE: Make sure the fasteners are installed in their proper locations as noted during removal.





3. Install the (A) Vehicle Speed Sensor (VSS) and the (B) bolt. Connect the (C) harness connector.





4. Install the (A) transmission insulator and retainer and the (B) bolts.





5. Lower the transmission jack while aligning the (A) transmission insulator and retainer studs with the holes in the (B) transmission support crossmember. Allow the full weight of the transmission to rest on the transmission support crossmember.





6. Install the transmission insulator and retainer-to-crossmember retaining nuts.





7. Remove the (A) High lift Transmission Jack with the (B) E40D Transmission Jack Adapter from the (C) transmission.





8. Reinstall the bolts removed to install the jack adapter.
9. Install the transmission-mounted parking brake assembly (if so equipped).
10. Install the driveshaft.
11. Remove the supports and lower the vehicle.
12. Connect the battery ground cable.
13. Fill the transmission to the specified level with MERCON (R) V Automatic Transmission Fluid XT-5-QM or MERCON(R) V equivalent.