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Transfer Case Rear Output Shaft Seal: Removal

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
    2. Fig 1: Identifying Front Flange, Driveshaft & Bolts
    GF0010634Courtesy of FORD MOTOR CO.
    CAUTION: Index-mark the front flange on the rear driveshaft and the flange on the transfer case.
  2. Disconnect the rear driveshaft from the transfer case and position the driveshaft aside.
    1. Index-mark the front flange on the driveshaft and the flange on the transfer case.
    2. Remove and discard the 4 bolts.
    3. Disconnect the driveshaft from the transfer case and position the driveshaft aside.
    3. Fig 2: View Of Washer, Nut And Alignment Marks
    GF0010635Courtesy of FORD MOTOR CO.
    CAUTION: Index-mark the rear output shaft and the flange.
    CAUTION: The nut has a self-locking feature. Discard the nut and the washer after removing them.
  3. Use the special tool to prevent the flange from turning. Remove and discard the nut and the washer.
  4. Using a suitable puller, remove the flange.
    Fig 3: Identifying Special Tool For Removing Flange
    GF0010636Courtesy of FORD MOTOR CO.
  5. Remove the oil seal if it remains on the rear output shaft.
    Fig 4: Identifying Oil Seal Remains On Rear Output Shaft
    GF0010637Courtesy of FORD MOTOR CO.
  6. Using the special tool, remove the oil seal.
    Fig 5: Identifying Special Tool For Removing Oil Seal
    GF0010638Courtesy of FORD MOTOR CO.
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