Transfer Case Rear Output Shaft Seal: Removal

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to JACKING AND LIFTING .
Index-mark the rear driveshaft and the transfer case rear flange to maintain driveline balance.

Fig 1: Identifying Index-Mark On Driveshaft And Transfer Case Flange
Courtesy of FORD MOTOR CO.
Remove and discard the four bolts.

Fig 2: Locating Rear Driveshaft Bolts And Alignment Marks
Courtesy of FORD MOTOR CO.
Disconnect the rear driveshaft from the transfer case and position it aside.
Remove and discard the nut.
- Use the special tool to prevent the flange from turning.
  
  Fig 3: Removing Flange Bolt
  Courtesy of FORD MOTOR CO.
Using the special tool, remove the flange.

Fig 4: Removing Flange
Courtesy of FORD MOTOR CO.
Using the special tools, remove the rear output seal.

Fig 5: Removing Rear Output Seal
Courtesy of FORD MOTOR CO.
Inspect the flange seal surface for wear and damage. Install a new flange, if necessary.