This procedure covers removal and replacement of the transmission output shaft bearing, requiring transmission removal from the vehicle and partial disassembly of the transmission tailhousing.

Warnings

Tools required

Parts

• Transmission output shaft bearing × 1 — Use OEM specification
• Transmission extension housing gasket/seal × 1 — Use OEM specification
• Transmission output shaft seal × 1 — Use OEM specification
• Transmission pan gasket × 1 — Use OEM specification
• Transmission drain plug crush washer × 1 — Use OEM specification
• Transfer case gasket × 1 — Use OEM specification
• Driveshaft U-joint strap bolts × 8 — Replace if damaged

Fluids

• Motorcraft MERCON LV ATF — 11 qt
• Motorcraft Transfer Case Fluid — 2.5 qt

Preparation

1. Ensure vehicle is on a lift or properly supported on jack stands with wheels chocked
2. Disconnect negative battery cable and wait 10 minutes for airbag system to deplete
3. Remove skid plates and underbody panels for transmission access
4. Place drain pan under transmission and drain fluid via drain plug, then remove transmission pan to fully drain
5. Mark driveshaft flanges and U-joint positions for proper reinstallation alignment
6. Support engine with engine support bar or hoist to prevent movement when transmission is removed
7. Tag and photograph all electrical connectors and vacuum lines for reference during reassembly

Procedure

1. 1

   Remove driveshafts and transfer case connections
   Remove front and rear driveshafts by removing U-joint strap bolts at differentials and transfer case. Mark orientation before removal. Disconnect transfer case shift motor electrical connector, vent hose, and speed sensor connections. Support transfer case with transmission jack.
2. 2

   Disconnect transmission electrical and cooler lines
   Disconnect transmission range sensor, solenoid body connector, turbine speed sensor, and output speed sensor. Disconnect transmission cooler lines at radiator side using line disconnect tool. Cap all openings immediately to prevent contamination. Remove transmission dipstick tube mounting bolt and remove tube.
3. 3

   Remove crossmember and transmission mounts
   Support transmission securely with transmission jack positioned at transmission pan rails. Remove rear crossmember bolts and lower crossmember. Remove transmission mount bolts from transmission and frame. Lower transmission slightly to gain access to upper bell housing bolts.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
4. 4

   Separate transmission from engine
   Remove all bell housing bolts securing transmission to engine block. Note bolt lengths and positions as they vary. Verify torque converter is secured to transmission with a safety strap or bolt through converter access hole. Carefully pull transmission straight back from engine, ensuring torque converter remains fully seated in transmission pump. Lower transmission from vehicle.
   ⚠️Torque converter must remain secured to transmission. If converter slides forward, pump bushing damage will occur.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
5. 5

   Remove transfer case from transmission
   With transmission on workbench, remove all bolts securing transfer case to transmission adapter. Separate transfer case from transmission by pulling straight back. Note position of any alignment dowels. Remove adapter plate if bearing replacement requires it.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Remove extension housing
   Remove extension housing bolts from rear of transmission case. Note that some housings use both bolts and screws of different lengths. Carefully tap extension housing with soft mallet to break gasket seal. Pull housing straight back off output shaft, being careful not to damage output shaft or lose any internal components.
   Torque spec

   Cover Screws12 Nm (9 lb-ft)
7. 7

   Remove output shaft seal and snap ring
   Remove output shaft seal from extension housing using seal puller or screwdriver. Remove snap ring from output shaft that retains bearing using snap ring pliers. Note orientation and position of snap ring and any shims or thrust washers behind it. Measure and record output shaft endplay before disassembly using dial indicator.
8. 8

   Extract output shaft bearing
   Using appropriate bearing puller, remove output shaft bearing from extension housing bore. If bearing is damaged, it may need to be split with chisel to remove. Clean extension housing bore thoroughly with solvent and inspect for scoring or damage. Measure bore diameter to verify it is within specification before installing new bearing.
   ⚠Do not damage extension housing bore during bearing removal. Scoring will cause premature bearing failure.
9. 9

   Install new output shaft bearing
   Place new bearing in freezer for 30 minutes before installation to aid installation. Clean extension housing bore with clean ATF. Using bearing driver or appropriately sized socket that contacts only outer bearing race, drive bearing squarely into housing until it seats against shoulder. Verify bearing is fully seated by measuring depth from housing face. Bearing should spin freely without rough spots.
   ⚠Drive bearing only on outer race. Driving on inner race or balls will damage bearing.
10. 10

    Measure and set output shaft endplay
    Install snap ring into groove on output shaft. Install extension housing onto transmission case with new gasket, leaving bolts slightly loose. Mount dial indicator on output shaft and measure endplay by moving shaft in and out. Endplay specification is typically 0.005-0.025 inches. Add or remove shims behind snap ring as needed to achieve proper endplay. Record final measurement.
    ⚠Incorrect endplay will cause bearing noise, premature wear, or transmission failure. Verify measurement is within specification.
11. 11

    Install extension housing and output seal
    Apply thin bead of RTV to extension housing mating surface if gasket requires it, or install new paper gasket dry. Install extension housing onto transmission case, ensuring alignment dowels are properly seated. Install and torque all extension housing bolts in criss-cross pattern. Install new output shaft seal using seal driver, ensuring seal lip faces inward toward transmission. Coat seal lip with ATF.
    Torque spec

    Cover Screws12 Nm (9 lb-ft)
12. 12

    Reinstall transfer case to transmission
    Clean all mating surfaces of transfer case adapter and transmission. Install new gasket or apply RTV as required. Align transfer case to transmission, ensuring output shaft engages transfer case input gear properly. Install all transfer case mounting bolts and torque to specification in star pattern.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
13. 13

    Install transmission into vehicle
    Raise transmission into position using transmission jack, ensuring torque converter remains fully seated. Align transmission to engine, rotating torque converter if needed to align with flexplate. Install all bell housing bolts and torque to specification, starting with upper bolts. Remove torque converter safety strap and install flexplate-to-converter bolts through access hole, torquing in star pattern.
    ⚠Verify torque converter is fully seated before bolting transmission to engine. Converter should be recessed approximately 1/2 inch from bell housing face.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)

    Flywheel Bolts95 Nm (70 lb-ft)
14. 14

    Reinstall mounts, crossmember, and driveshafts
    Install transmission mount bolts and torque to specification. Raise transmission into position and install rear crossmember, torquing all bolts to specification. Reconnect front and rear driveshafts, aligning marks made during removal and torquing U-joint strap bolts to specification. Reconnect all transfer case electrical connectors, vent hose, and speed sensors.
    Torque spec

    Mounting Bolts31 Nm (23 lb-ft)
15. 15

    Reconnect lines and refill fluids
    Reconnect transmission cooler lines using new O-rings if equipped. Reconnect all transmission electrical connectors including range sensor, solenoid body, and speed sensors. Reinstall transmission dipstick tube. Install new drain plug crush washer and torque drain plug to specification. Install transmission pan with new gasket, torquing pan bolts in criss-cross pattern. Fill transmission with MERCON LV ATF to proper level. Refill transfer case with proper fluid to specification.
    Torque spec

    Transmission Drain Plug30 Nm (22 lb-ft)

    Pan Bolts19 Nm (14 lb-ft)

    Sensor Bolts12 Nm (9 lb-ft)

Reassembly

1. Verify all electrical connectors are fully seated and locked
2. Check that all driveshaft U-joint bolts are properly torqued and safety wired if equipped
3. Ensure transmission dipstick tube is fully seated and secured
4. Double-check transmission fluid level with engine running in Park on level ground
5. Reinstall all skid plates and underbody panels removed for access

Verification

• With engine running, shift through all gear ranges and verify smooth engagement with no harsh shifts or slipping
• Check for transmission fluid leaks at pan, extension housing, cooler lines, and all sensor locations
• Test drive vehicle and verify proper shift points, no noise from output shaft bearing area, and proper 4WD engagement
• Verify no Check Engine Light or transmission fault codes using scan tool
• Recheck transmission fluid level after test drive and top off if necessary
• Listen for any abnormal bearing noise from transmission during acceleration and deceleration
• Verify output shaft endplay was properly set by confirming no axial movement or clunking during engagement

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