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Old 10-16-2005, 16:01   #1 (permalink)
Ford Warrior
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Transmission extension housing removal?

Hiya

In an attempt to correct some deep vibration I get when driving 55-65mph,
I'm going to be replacing the extension housing seal and bushing on my 1995
Ford E250 4.9L L6. I've already replaced the u-joints. The seal has some
tears and leaks a bit and there is a lot of play on the output shaft of the
transmission. The transmission itself is the 3-speed C6. In the Ford
factory manual they describe the process of replacing the bushing as not
requiring removal of the entire extension housing because they tell you to
use this special bushing removal tool that actually allows you to insert it
from the driveshaft end of the housing and then 'pull' the bushing out
using the tool's fingers... the problem is I can't find this tool at any of
the auto parts shops around town and have only been able to find a set of
bushing drivers that allow you to tap out the old bushing. This requires
complete removal of the extension housing, but this process is not
described in any of the 3 manuals I have. Will I have to remove the entire
transmission? If not, will I still have to drain out the transmission
fluid? Is there anything difficult about removing the extension housing?
basically just give me the inside scoop on this. I figure it's probably an
easy task, but I wanted to get some advice from the pros here before I end
up screwing something up major.

Or Is there any chance I could find a special tool like the one described in
the Ford manual at a hardware store or Home Depot? What could I look for?

take care
Jay
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Old 10-17-2005, 04:01   #2 (permalink)
pater
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Re: Transmission extension housing removal?

Should unbolt easily & come right off, if I remember correctly. The
only hitch may be if the trans mount is on the tailshaft extension, in
which case you'll just have to support the trans during your repair.
It's best to use a press to install the new one. Test fit it over the
driveshaft before you bolt it back together. Good luck.

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Old 10-17-2005, 10:01   #3 (permalink)
will350@eskimo.com
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Re: Transmission extension housing removal?

R&R on the housing should be straight forward ( easy ) Jack up the
trans , block it up , pull the rear mount( maybe cross member too ) ,
pull the speedo cable and anything else that's plugged into it ,put a
drain pan under it , take it off .
Before you do that though , you might want to take a really good
look at the drive shaft for a slight bend and or missing balance weight
..
If this just "happened all of a sudden " vs " over time " think back
to any incidents . Give the rear end yoke a couple of good yanks too .
Any play in that can give you fits and doesn't "always" make the rear
end scream . Haven't seen very many bushings go south and if it
has,something is making that happen .
Will



Ford Warrior wrote:
> Hiya
>
> In an attempt to correct some deep vibration I get when driving 55-65mph,
> I'm going to be replacing the extension housing seal and bushing on my 1995
> Ford E250 4.9L L6. I've already replaced the u-joints. The seal has some
> tears and leaks a bit and there is a lot of play on the output shaft of the
> transmission. The transmission itself is the 3-speed C6. In the Ford
> factory manual they describe the process of replacing the bushing as not
> requiring removal of the entire extension housing because they tell you to
> use this special bushing removal tool that actually allows you to insert it
> from the driveshaft end of the housing and then 'pull' the bushing out
> using the tool's fingers... the problem is I can't find this tool at any of
> the auto parts shops around town and have only been able to find a set of
> bushing drivers that allow you to tap out the old bushing. This requires
> complete removal of the extension housing, but this process is not
> described in any of the 3 manuals I have. Will I have to remove the entire
> transmission? If not, will I still have to drain out the transmission
> fluid? Is there anything difficult about removing the extension housing?
> basically just give me the inside scoop on this. I figure it's probably an
> easy task, but I wanted to get some advice from the pros here before I end
> up screwing something up major.
>
> Or Is there any chance I could find a special tool like the one described in
> the Ford manual at a hardware store or Home Depot? What could I look for?
>
> take care
> Jay


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Old 10-17-2005, 10:01   #4 (permalink)
Guest
 
Posts: n/a
Re: Transmission extension housing removal?

Nope, you wont find that tool at a Home Depot.
I think the ones I have seen look like a little "L", that attach to a slide
hammer
(dent remover), etc. They are thin enough you can slip them past the seal
and then tap the seal out. Similar with bushing.

You can probably order one that will work. SnapOn must have one, and even
JC Whitney might have a cheap unit.

If I remember correctly, you can get the seal out and replaced with pretty
low
level tools alone. Are you sure you need to replace the bushing?


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Old 10-17-2005, 10:01   #5 (permalink)
will350@eskimo.com
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Posts: n/a
Re: Transmission extension housing removal?

R&R on the housing should be straight forward ( easy ) Jack up the
trans , block it up , pull the rear mount( maybe cross member too ) ,
pull the speedo cable and anything else that's plugged into it ,put a
drain pan under it , take it off .
Before you do that though , you might want to take a really good
look at the drive shaft for a slight bend and or missing balance weight
..
If this just "happened all of a sudden " vs " over time " think back
to any incidents . Give the rear end yoke a couple of good yanks too .
Any play in that can give you fits and doesn't "always" make the rear
end scream . Haven't seen very many bushings go south and if it
has,something is making that happen .
Will



Ford Warrior wrote:
> Hiya
>
> In an attempt to correct some deep vibration I get when driving 55-65mph,
> I'm going to be replacing the extension housing seal and bushing on my 1995
> Ford E250 4.9L L6. I've already replaced the u-joints. The seal has some
> tears and leaks a bit and there is a lot of play on the output shaft of the
> transmission. The transmission itself is the 3-speed C6. In the Ford
> factory manual they describe the process of replacing the bushing as not
> requiring removal of the entire extension housing because they tell you to
> use this special bushing removal tool that actually allows you to insert it
> from the driveshaft end of the housing and then 'pull' the bushing out
> using the tool's fingers... the problem is I can't find this tool at any of
> the auto parts shops around town and have only been able to find a set of
> bushing drivers that allow you to tap out the old bushing. This requires
> complete removal of the extension housing, but this process is not
> described in any of the 3 manuals I have. Will I have to remove the entire
> transmission? If not, will I still have to drain out the transmission
> fluid? Is there anything difficult about removing the extension housing?
> basically just give me the inside scoop on this. I figure it's probably an
> easy task, but I wanted to get some advice from the pros here before I end
> up screwing something up major.
>
> Or Is there any chance I could find a special tool like the one described in
> the Ford manual at a hardware store or Home Depot? What could I look for?
>
> take care
> Jay


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Old 10-17-2005, 12:01   #6 (permalink)
Shep
Guest
 
Posts: n/a
Re: Transmission extension housing removal?

That tool is for sure part of the special tools for Ford dealers, most trans
shops have something similar, to buy a set for one job is too expensive,
usually removing the ext housing is not a big deal, but you might want to
check with some one who's done this on a Ford.
"Ford Warrior" <fordwarrior@fordwarrior.com> wrote in message
news:A9z4f.6685$lN2.6591@fe04.lga...
> Hiya
>
> In an attempt to correct some deep vibration I get when driving 55-65mph,
> I'm going to be replacing the extension housing seal and bushing on my
> 1995
> Ford E250 4.9L L6. I've already replaced the u-joints. The seal has some
> tears and leaks a bit and there is a lot of play on the output shaft of
> the
> transmission. The transmission itself is the 3-speed C6. In the Ford
> factory manual they describe the process of replacing the bushing as not
> requiring removal of the entire extension housing because they tell you to
> use this special bushing removal tool that actually allows you to insert
> it
> from the driveshaft end of the housing and then 'pull' the bushing out
> using the tool's fingers... the problem is I can't find this tool at any
> of
> the auto parts shops around town and have only been able to find a set of
> bushing drivers that allow you to tap out the old bushing. This requires
> complete removal of the extension housing, but this process is not
> described in any of the 3 manuals I have. Will I have to remove the
> entire
> transmission? If not, will I still have to drain out the transmission
> fluid? Is there anything difficult about removing the extension housing?
> basically just give me the inside scoop on this. I figure it's probably
> an
> easy task, but I wanted to get some advice from the pros here before I end
> up screwing something up major.
>
> Or Is there any chance I could find a special tool like the one described
> in
> the Ford manual at a hardware store or Home Depot? What could I look for?
>
> take care
> Jay
>




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Old 10-18-2005, 04:01   #7 (permalink)
sdlomi2
Guest
 
Posts: n/a
Re: Transmission extension housing removal?


"Ford Warrior" <fordwarrior@fordwarrior.com> wrote in message
news:A9z4f.6685$lN2.6591@fe04.lga...
> Hiya
>
> In an attempt to correct some deep vibration I get when driving 55-65mph,
> I'm going to be replacing the extension housing seal and bushing on my
> 1995
> Ford E250 4.9L L6. I've already replaced the u-joints. The seal has some
> tears and leaks a bit and there is a lot of play on the output shaft of
> the
> transmission. The transmission itself is the 3-speed C6. In the Ford
> factory manual they describe the process of replacing the bushing as not
> requiring removal of the entire extension housing because they tell you to
> use this special bushing removal tool that actually allows you to insert
> it
> from the driveshaft end of the housing and then 'pull' the bushing out
> using the tool's fingers... the problem is I can't find this tool at any
> of
> the auto parts shops around town and have only been able to find a set of
> bushing drivers that allow you to tap out the old bushing. This requires
> complete removal of the extension housing, but this process is not
> described in any of the 3 manuals I have. Will I have to remove the
> entire
> transmission? If not, will I still have to drain out the transmission
> fluid? Is there anything difficult about removing the extension housing?
> basically just give me the inside scoop on this. I figure it's probably
> an
> easy task, but I wanted to get some advice from the pros here before I end
> up screwing something up major.
>
> Or Is there any chance I could find a special tool like the one described
> in
> the Ford manual at a hardware store or Home Depot? What could I look for?
>
> take care
> Jay

Not exactly the answer u asked, but have u tried Auto Zone and Advance
A/Parts to see if they have that tool in their tool-loaner program? Just a
thought & hth, s


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Old 10-18-2005, 09:01   #8 (permalink)
lugnut
Guest
 
Posts: n/a
Re: Transmission extension housing removal?

On Sun, 16 Oct 2005 16:01:39 -0500, Ford Warrior
<fordwarrior@fordwarrior.com> wrote:

>Hiya
>
>In an attempt to correct some deep vibration I get when driving 55-65mph,
>I'm going to be replacing the extension housing seal and bushing on my 1995
>Ford E250 4.9L L6. I've already replaced the u-joints. The seal has some
>tears and leaks a bit and there is a lot of play on the output shaft of the
>transmission. The transmission itself is the 3-speed C6. In the Ford
>factory manual they describe the process of replacing the bushing as not
>requiring removal of the entire extension housing because they tell you to
>use this special bushing removal tool that actually allows you to insert it
>from the driveshaft end of the housing and then 'pull' the bushing out
>using the tool's fingers... the problem is I can't find this tool at any of
>the auto parts shops around town and have only been able to find a set of
>bushing drivers that allow you to tap out the old bushing. This requires
>complete removal of the extension housing, but this process is not
>described in any of the 3 manuals I have. Will I have to remove the entire
>transmission? If not, will I still have to drain out the transmission
>fluid? Is there anything difficult about removing the extension housing?
>basically just give me the inside scoop on this. I figure it's probably an
>easy task, but I wanted to get some advice from the pros here before I end
>up screwing something up major.
>
>Or Is there any chance I could find a special tool like the one described in
>the Ford manual at a hardware store or Home Depot? What could I look for?
>
>take care
>Jay



If you are talking about tears in the seal boot, that is not
a big problem. Replacement seals do not have a boot like
the original. For a one time bushing job, I would simply
unbolt the rear mount, jack it up, remove the rear mount and
remove the housing. Loss of fluid won't be much and you
will be able drive out the old seal and bushing easily. The
bushing can be reseated with a universal seal and bushing
driver. Be sure to check the yoke for wear also. If you
are getting driveline vibration for sure, you need to check
the center support carefully. Also, if the U-joints were
assembled too tight, that can cause a vibration if the
vibration started after they were replaced. The pinion is
also a source of vibration if the bearings are failing.
Over the years, I have started to just have a local drive
line shop do U-joints since they need to be rebalance about
half the time after joint replacement. They replaced the
center support bearing and all the U-joints along with a
rebalance in my F150 shaft a few months ago for less than a
hundred bucks with me laying the shaft on the counter.

Lugnut
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Old 10-19-2005, 02:01   #9 (permalink)
Ted Mittelstaedt
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Re: Transmission extension housing removal?


"Ford Warrior" <fordwarrior@fordwarrior.com> wrote in message
news:A9z4f.6685$lN2.6591@fe04.lga...
> Hiya
>
> In an attempt to correct some deep vibration I get when driving 55-65mph,


Before you tear into it, check the driveshaft alignment. A misalignment of
more
than a few degrees will cause a resonance at a certain speed. Basically the
yoke and the shaft going into the rear differential must be perfectly
parallel.

Ted


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Old 10-19-2005, 10:01   #10 (permalink)
Ford Warrior
Guest
 
Posts: n/a
Re: Transmission extension housing removal?

Ted Mittelstaedt wrote:

>
> "Ford Warrior" <fordwarrior@fordwarrior.com> wrote in message
> news:A9z4f.6685$lN2.6591@fe04.lga...
>> Hiya
>>
>> In an attempt to correct some deep vibration I get when driving 55-65mph,

>
> Before you tear into it, check the driveshaft alignment. A misalignment
> of more
> than a few degrees will cause a resonance at a certain speed. Basically
> the yoke and the shaft going into the rear differential must be perfectly
> parallel.
>
> Ted



If there were a misalignment between the differential and the yolk end, How
would I correct this? I'm assuming in this case, driveshaft balancing or
even buying a new driveshaft wouldn't fix the problem, right?

thanks
Jay
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