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Transfer Case Rear Output Shaft Oil Seal: Installation

WARNING: This page is about a different car, the 2004 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
    G03276396Courtesy 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
    G03276397Courtesy 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 N.m (40 lb-ft) to seat the flange on the shaft.
    Fig 3: Installing Flange
    G03276398Courtesy 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 Flange Washer And Nut
    G03276399Courtesy 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
    G03276400Courtesy 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 AND FILLING .
  9. Lower the vehicle.
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