Extension Housing: Service and Repair

Extension Housing

Removal
1. With the vehicle in NEUTRAL, raise and support the vehicle.





2. Remove the drain plug and drain the transmission fluid.





3. NOTE: To maintain initial driveshaft balance, index-mark the driveshaft to the rear axle pinion flange so it can be installed in its original position.

Remove and support the rear driveshaft.

4. Remove the transfer case, if equipped.





5. Using the special tool, support the transmission.
^ Secure the transmission with a strap.





6. Remove the six crossmember bolts.





7. Remove the nuts, then remove the crossmember.





8. Remove the transmission mount.
1 Remove the bolts.
2 Reposition the exhaust mounting bracket.





9. Remove the extension housing.
^ 4x2 shown, 4x4 similar.

Installation





1. Install the extension housing.





2. Install the transmission mount.
1 Position the exhaust bracket.
2 Install the bolts.





3. Position the crossmember and install the six bolts and nuts.
4. Remove High-Lift Transmission Jack.





5. Install the nuts.
6. Install the transfer case, if equipped.

7. NOTE: To maintain initial driveshaft balance, align the index marks on the driveshaft and the rear axle pinion flange made during removal.

Install the rear driveshaft.





8. Install the drain plug.
9. Refill the transmission with the specified amount of fluid.
^ Use MERCON Multipurpose Automatic Transmission Fluid XT-2-QDX or equivalent meeting Ford specification MERCON.
10. Lower the vehicle.