Seals and Gaskets: Service and Repair

Special Tools:

Removal
1. Turn the air suspension switch OFF.
2. Disconnect the battery ground cable.
3. Raise the vehicle on a hoist.
4. Drain the transmission fluid.

NOTE: To maintain the initial driveshaft balance, mark the rear driveshaft yoke and the axle flange so they may be installed in their original positions.





5. Remove the driveshaft.
^ Remove the four bolts.





6. Separate the driveshaft from the transmission.
7. Use a High-Lift Transmission Jack to support the transmission.





8. Remove the two transmission mount nuts.





9. Remove the transmission crossmember.
^ Remove the bolts.
^ Remove the transmission crossmember.
10. Lower the transmission to access the extension housing bolts.





11. Use the (A) Seal Remover and the (B) Impact Slide Hammer to remove the (c) extension housing seal.





12. Remove the extension housing and gasket.
1. Remove the bolts and the nuts.
2. Remove the extension housing and gasket.

Installation





1. Install the extension housing and gasket.
1. Position the extension housing gasket and the extension housing.
2. Install the bolts and the nuts.





2. Install the new extension housing seal.
1. Align Extension Housing Seal Replacer with the seal.
2. Install the extension housing seal.
3. Raise and position the transmission.





4. Install the transmission crossmember.
1. Position the transmission crossmember.
2. Install the bolts.
5. Remove High-Lift Transmission Jack.





6. Install the two transmission mount nuts.

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





7. Install the driveshaft.
^ Align the yellow dots and position the driveshaft on the transmission.
^ Position the driveshaft to the rear differential.





8. Install the four retaining bolts.
9. Lower the vehicle.
10. Connect the battery ground cable.
11. If equipped reactivate the air suspension.
12. Fill the transmission with fluid and inspect for proper operation.
^ Use Motorcraft MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting Ford specification MERCON(R) V.