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Transfer Case Rear Output Shaft Oil Seal: Installation

WARNING: This page is about a different car, the 2002 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean the seal mounting surface.
  2. Using the special tool, install the new oil seal.
    Fig 1: Installing Oil Seal
    G02153289Courtesy of FORD MOTOR CO.
    3. CAUTION: Align the index marks.
    NOTE: Be sure the oil seal is not on the shaft before installing the flange.
    Fig 2: Positioning Flange On Rear Output Shaft
    G02153290Courtesy of FORD MOTOR CO.
  3. Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.
  4. Install a new oil seal in the flange.
  5. Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.
    Fig 3: Installing Flange
    G02153291Courtesy of FORD MOTOR CO.
  6. Use the special tool to prevent the flange from turning. Install a new washer and a new nut.
    Fig 4: Installing Washer & Nut
    G02153292Courtesy of FORD MOTOR CO.
    7. CAUTION: Align the index marks.
    NOTE: Install the driveshaft with new bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
    Fig 5: Connecting Driveshaft To Transfer Case
    G02153293Courtesy of FORD MOTOR CO.
  7. Connect the driveshaft to the transfer case and install the bolts.
  8. Check the transfer case fluid level. If necessary, fill the transfer case to the correct level with the specified fluid. For additional information, refer to TRANSFER CASE DRAINING & FILLING .
  9. Lower the vehicle.
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