Transfer Case Front Output Shaft Seal

WARNING: This page is about a different variant/trim than selected.

SPECIAL TOOLS CHART

Holding Fixture, Transmission
307-003 (T57L-500-B)

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the transfer case. For additional information, refer to TRANSFER CASE in this service information.

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 exterior with solvent and dry with compressed air.
Using the Transmission Holding Fixture, secure the transfer case to a work bench. Rotate the transfer case so the rear output shaft is pointing upward.

Fig 1: Rotating Transfer Case Rear Output Shaft Pointing Upward
Courtesy of FORD MOTOR CO.
Remove the coil wire pin from the electrical connector.
- Remove the wire connector inner retainer.
- Press the release tab and remove the coil wire pin (tan wire).
  
  Fig 2: Locating Coil Wire Pin In Electrical Connector
  Courtesy of FORD MOTOR CO.
Remove the transfer case shift motor.
1. Loosen the 2 transfer case shift motor bracket nuts.
2. Remove the transfer case shift motor bracket bolt.
3. Remove the 3 transfer case shift motor bolts.
  
  Fig 3: Identifying Transfer Case Shift Motor Bolts
  Courtesy of FORD MOTOR CO.
Remove the 3 coil nuts and washers.

Fig 4: Locating Coil Nuts And Washers
Courtesy of FORD MOTOR CO.

NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.

Fig 5: Locating Transfer Case Cover Bolts

Courtesy of FORD MOTOR CO.

Remove the 20 transfer case cover bolts.
Using the pry bosses, separate the transfer case halves.

Fig 6: Separating Transfer Case Halves
Courtesy of FORD MOTOR CO.
Remove the snap ring.
- Inspect the snap ring for wear or damage. Install a new snap ring if necessary.
  
  Fig 7: Locating Snap Ring
  Courtesy of FORD MOTOR CO.
Remove the spacer.

Fig 8: Locating Spacer
Courtesy of FORD MOTOR CO.
Remove the caged thrust bearing assembly.
- Inspect the bearing for wear or damage. Install a new bearing as necessary.
  
  Fig 9: Locating Caged Thrust Bearing Assembly
  Courtesy of FORD MOTOR CO.
Remove the cam/coil housing.

Fig 10: Locating Cam/Coil Housing
Courtesy of FORD MOTOR CO.
Remove the 3 steel balls and the cam.

Fig 11: Locating Steel Balls And Cam
Courtesy of FORD MOTOR CO.
Remove the wave spring.

Fig 12: Locating Wave Spring
Courtesy of FORD MOTOR CO.
Remove and discard the snap ring.

Fig 13: Locating Snap Ring
Courtesy of FORD MOTOR CO.

NOTE: When removing the clutch pack assembly, do not separate the clutch pack assembly. Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in the same position as located in the transfer case. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.

NOTE: If the clutch pack is disassembled, a new clutch pack must be installed and the armature transferred. Failure to install a new clutch pack can result in component failure.

Fig 14: Locating Clutch Pack Assembly

Courtesy of FORD MOTOR CO.

Remove the clutch pack assembly with the armature.
Remove the drive chain and the sprockets as an assembly.
- Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth. Install new components as necessary.
  
  Fig 15: Locating Drive Chain And Sprockets Assembly
  Courtesy of FORD MOTOR CO.
Remove the driven sprocket spacer.

Fig 16: Locating Driven Sprocket Spacer
Courtesy of FORD MOTOR CO.

NOTE: Do not let the front output shaft fall when removing the snap ring.

Remove the snap ring and the front output shaft.
- Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
  
  Fig 17: Locating Snap Ring And Front Output Shaft
  Courtesy of FORD MOTOR CO.

NOTE: Carefully remove the seal, do not damage the seal bore.

Fig 18: Locating Front Output Shaft Oil Seal

Courtesy of FORD MOTOR CO.

Remove and discard the front output shaft seal.