Seals and Gaskets: 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.

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

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

5. CAUTION: Do not damage any machined surfaces. The new seal may leak.

Using the (A) Extension Housing Bushing Remover, (model dependent) remove t1fe (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. Damage to new bushing may occur.

Note: The extension housing bushing is model dependent.

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

3. Note: The extension housing seal is model dependent.

Align the (A) extension housing seal in the extension housing, with the (B) drain hole positioned downward.

4. Using the (A) Extension Housing Seal Replacer (model dependent), 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 V (R) Multi-Purpose (ATF) Transmission Fluid XT-5-QM or equivalent meeting MERCON9 specification.