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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1181 (Transfer Case - Electronic Shift) >> In-Vehicle Repair >> Transfer Case Rear Output Shaft Seal >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the transmission in NEUTRAL, raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
  2. Index mark the rear output flange and the driveshaft yoke.
    Fig 1: Identifying Index Mark Rear Output Flange And Driveshaft Yoke
    G03912442Courtesy of FORD MOTOR CO.
    3. CAUTION: If new driveshaft yoke bolts are not available, coat the threads of the original bolts with threadlock and sealer.
    Fig 2: Locating Driveshaft Yoke Bolts
    G03912443Courtesy of FORD MOTOR CO.
  3. Remove the 4 driveshaft yoke bolts.
    • To install, tighten the bolts to 112 Nm (83 lb-ft) evenly in a cross pattern.
    4. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange.
    Fig 3: Disconnecting Driveshaft Flange Yoke From Pinion Flange
    G03878446Courtesy of FORD MOTOR CO.
  4. Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle pinion flange.
  5. Position the driveshaft aside and support with mechanic's wire.
    Fig 4: Positioning Driveshaft Aside And Supporting With Mechanic's Wire
    G03949498Courtesy of FORD MOTOR CO.
  6. Index mark the rear output flange and the upper output shaft.
    Fig 5: Identifying Index Mark Rear Output Flange And Upper Output Shaft
    G03949499Courtesy of FORD MOTOR CO.
  7. Using the special tool to hold the output flange, remove the nut.
    • To install, tighten to 355 Nm (262 lb-ft).
    Fig 6: Removing Nut
    G03949500Courtesy of FORD MOTOR CO.
  8. Remove the output shaft yoke washer.
  9. Remove the rear output shaft flange.
  10. Remove and discard the rear output shaft flange oil seal.
  11. Using the special tools, remove the rear output shaft oil seal.
    Fig 7: Removing Rear Output Shaft Oil Seal
    G03949501Courtesy of FORD MOTOR CO.
  12. To install, reverse the removal procedure.
    • Always install a new rear output shaft flange oil seal.
  13. Using the special tool, install a new rear output shaft oil seal.
    Fig 8: Installing Rear Output Shaft Oil Seal
    G03949502Courtesy of FORD MOTOR CO.
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