Extension Housing Gasket: Installation

All vehicles

NOTE: 4x2 shown, 4x4 similar.

Install the extension housing and a new gasket.
1. Position the extension housing gasket and the extension housing.
2. Install the bolts and nuts.
  - Tighten to 27 N.m (20 lb-ft).
    
    Fig 1: Identifying Extension Housing & Gasket
    Courtesy of FORD MOTOR CO.
Install the fuel line bracket.
- Tighten to 25 N.m (18 lb-ft).
  
  Fig 2: Locating Fuel Line Bracket Bolt
  Courtesy of FORD MOTOR CO.
Raise and position the transmission.
Position the exhaust hanger, the rear transmission insulator and install the bolts.
- Tighten to 80 N.m (59 lb-ft).
  
  Fig 3: Locating Exhaust Hanger & Rear Transmission Insulator Bolts
  Courtesy of FORD MOTOR CO.
Install the exhaust bracket nut.
- Tighten to 40 N.m (30 lb-ft).
  
  Fig 4: Locating Exhaust Bracket Nut
  Courtesy of FORD MOTOR CO.
Position the crossmember and loosely install the transmission mount-to-crossmember nut.

Fig 5: Identifying Transmission Mount-To-Crossmember Nuts
Courtesy of FORD MOTOR CO.
Install the crossmember-to-frame bolts.
- Tighten to 90 N.m (66 lb-ft).
  
  Fig 6: Locating Crossmember-To-Frame Bolts
  Courtesy of FORD MOTOR CO.
Lower the transmission on the crossmember and tighten the rear mount nuts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 7: Identifying Transmission Mount-To-Crossmember Nuts
  Courtesy of FORD MOTOR CO.

NOTE: 4x2 shown, 4x4 similar.

Fig 8: Locating Transmission Jack

Courtesy of FORD MOTOR CO.

Remove the high-lift transmission jack.
Install the 2 bolts retaining the heat shield to the transmission support crossmember.
- Tighten to 15 N.m (11 lb-ft).
  
  Fig 9: Locating Heat Shield Bolt
  Courtesy of FORD MOTOR CO.

4x4 vehicles

Install the transfer case. For additional information, refer to TRANSFER CASE 2005 TRANSFER CASE 2006 .

4x2 vehicles

NOTE: The output shaft and the driveshaft are a balanced assembly.

Install the driveshaft.
- Align the yellow dots and position the driveshaft on the transmission.
  
  Fig 10: Installing Drive Shaft
  Courtesy of FORD MOTOR CO.

NOTE: To maintain driveshaft balance, install the driveshaft yoke and flange in the original position that was marked during removal.

Install the rear driveshaft and the 4 bolts.
- Tighten to 103 N.m (76 lb-ft).
  
  Fig 11: Identifying Driveshaft Bolts
  Courtesy of FORD MOTOR CO.

All vehicles

Lower the vehicle.
Fill the transmission with clean automatic transmission fluid.
- Verify for correct operation.
- Check for leaks.