Transfer Case Front Output Shaft Seal - Vehicles With: Electronic Shift Transfer Case: Removal

WARNING: This page is about a different car, the 2020 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

Remove the transfer case. Refer to: Transfer Case .
NOTE: Seal all openings before cleaning the transfer case exterior. This will prevent entry of dirt and water, which may cause damage to internal components.

Clean the transfer case with solvent and dry with compressed air.
Using a transmission adjustable mounting arm, secure the transfer case to the bench. Use the General Equipment: Adjustable Mounting Arm

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Remove the transfer case rear seal. Refer to: Transfer Case Rear Seal .
Remove the coil wire pin from the electrical connector.
1. Remove the inner retainer from the wire connector.
2. Press the release tab and remove the coil wire pin.
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1. Loosen the transfer case shift motor bracket nuts.
2. Remove the transfer case shift motor bracket bolt.
3. Remove the transfer case shift motor bolts.
4. Remove the transfer case shift motor.
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Clean the transfer case shift motor mating surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Remove the coil nuts and washers.

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NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing the cover.

Remove the transfer case bolts.

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NOTE: Use care not damage the field coil wire.

Using the pry bosses, separate the transfer case covers.

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Remove the transfer case field coil.

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Remove the field coil housing snap ring.

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Remove the field coil housing.

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Remove the lock up hub, shift fork and shift fork spring.

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NOTE: Remove the drive chain and sprockets as an assembly.

Remove the drive chain and sprockets.

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NOTE: Do not let the front output shaft fall while removing the snap ring or damage to the component may occur.

Remove the output shaft circlip and the out put shaft.

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Remove and discard the front output shaft seal.

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Using the special tool with the Slide Hammer, remove the front output shaft bearing. Use Special Service Tool: 308-047 (T77F-1102-A) Remover, Bearing Cup. Use the General Equipment: Slide Hammer

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