Extension Housing: Service and Repair

Special Tools:

Removal

1. 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.

Note: All gasoline vehicles will have new adaptive shift strategies. Whenever the vehicles battery has been disconnected for any type of service or repairs the strategy parameters that are stored in the Keep Alive Memory (KAM) will be lost. The strategy will start to relearn once the battery is reconnected and the vehicle is driven. This is a temporary condition and will return to normal operating condition once the Powertrain Control Module (PCM) relearns all the parameters from the driving operating conditions. There is no time frame set for this process. If a concern is present during down shifts or converter clutch apply, it is not the shift strategy and will require diagnosis.

The customer needs to be notified that they may experience slightly different upshifts either soft or firm and that this condition is temporary and will eventually return to normal operating condition.
- Disconnect the battery ground cable.

2. Raise and support the vehicle.
3. Remove the driveshaft.





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





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

6. CAUTION: Be sure not to raise the back of the transmission too high. If it makes contact with the underbody, damaged to the TSS sensor should occur.





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





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





8. If equipped disconnect the (A) harness connector and position it aside. Remove the (B) bolt and the (C) Vehicle Speed Sensor (VSS).

9. Note: Econoline Super Duty applications use a special extension housing similar to 44.

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





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

Installation

1. CAUTION: 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.

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





Install the new extension housing gasket.
- Verify that the extension has a shoulder cast in it.
- Install the new extension housing gasket.

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





Install the (A) extension housing, the 8 (13) bolts and the (C) stud.





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

4. CAUTION: Be sure not to raise the back of the transmission too high. If it makes contact with the underbody, damaged to the TSS sensor should occur.





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. Lower the vehicle.
12. Connect the battery ground cable.
13. Fill the transmission to the specified level with Motorcraft MERCON V (R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting MERCON V (R) specification.