Transfer Case Input Shaft Seal: Removal

WARNING: This page is about a different car, the 2018 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.

Remove the PTU (Power Transfer Unit). Refer to: Transfer Case .
Using the special tool, secure the PTU to the bench. Use Special Service Tool: 307-003 (T57L-500-B) Holding Fixture, Transmission.

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Remove and discard the compression seal.

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NOTE: Do not press the seals lower than specified. Excessive force will damage the bearing below the seals.

NOTE: Both seals will need to be pressed lower into the transfer case input shaft opening to break the seals outer sealant loose from the transfer case.

NOTE: There is approximately a 5 mm (0.196 in) air gap between both seals and approximately 1 mm (0.039 in) air gap between the inner seal and the bearing race.
Using the special tool, press the outer seal downward until the lower seal contacts the bearing race. Use Special Service Tool: 206-040 (T88T-2598-F) Installer, Parking Brake Bearing.

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Position the special tool above the PTU input shaft opening. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Insert the special tool into one of the screw guide holes. Press the special tool downward until the shoulder of the punch touches the screw guide. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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NOTE: Do not overtighten the screws. Turn the 308-777 /3 until they are seated into the screw guide holes.

Install the special tool into the screw guide hole. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Insert the special tool into the opposing screw guide hole. Press the special tool downward until the shoulder of the punch touches the screw guide. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Install the special tool into the screw guide hole. Use Special Service Tool: 308-777 Remover and Installer, PTU Input Shaft Seal.

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Using the special tools, remove and discard the 2 input shaft seals. Use Special Service Tool: 100-001 (T50T-100-A) Slide Hammer, 308-777 Remover and Installer, PTU Input Shaft Seal.

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Drain the transfer case.
Position the transfer case output flange upward and tilt the transfer case approximately 30 degrees toward the LH seal bore to allow the fluid to drain from the transfer case input shaft opening.