Ford Explorer: Transfer Case / Removal and Installation - Transfer Case Rear Seal

Special Tool(s) / General Equipment

	205-072 Universal Flange Holding Wrench
	205-1018 Installation Tube
	205-1067 Installer, Output Shaft AWD
	205-D027 (D80L-1013-A) 2 or 3 Jaw Puller

Removal

1. With the vehicle in NEUTRAL, position it on a hoist.
   Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
   

1. Remove the rear driveshaft.
   Refer to: Rear Driveshaft (205-01 Driveshaft, Removal and Installation).
   

1. Drain the transfer case.
   

1. Remove the exhaust flexible pipe.
   Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Exhaust Flexible Pipe (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   Refer to: Exhaust Flexible Pipe (309-00C Exhaust System - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Exhaust Flexible Pipe (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Remove the muffler and tailpipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00C Exhaust System - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. NOTE: Note the position of the component before removal.

   Using the tool, hold the flange and remove the flange nut.
   Use Special Service Tool: 205-072  Universal Flange Holding Wrench.

1. Remove and discard the flange nut washer.
   

1. Remove and discard the flange nut seal.
   

1. Using the tool, remove the output flange.
   Use Special Service Tool: 205-D027 (D80L-1013-A)  2 or 3 Jaw Puller.

1. Remove and discard the transfer case rear output shaft seal.
   

Installation

1. Install the special tool to the seal.
   Use Special Service Tool: 205-1018  Installation Tube. , 205-1067  Installer, Output Shaft AWD.

1. Using the special tool, install the transfer case rear seal.
   Use Special Service Tool: 205-1018  Installation Tube. , 205-1067  Installer, Output Shaft AWD.

1. Install the transfer case output flange.
   

1. Install the flange nut seal.
   

1. Install the flange nut washer.
   

1. Using the tool, hold the flange and install the flange nut.
   Use Special Service Tool: 205-072  Universal Flange Holding Wrench.
   Torque: 203 lb.ft (275 Nm)

1. Refill the transfer case.
   

1. Install the muffler and tailpipe.
   Refer to: Muffler and Tailpipe (309-00A Exhaust System - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00C Exhaust System - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Muffler and Tailpipe (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Install the exhaust flexible pipe.
   Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 2.3L EcoBoost (201kW/273PS), Removal and Installation).
   Refer to: Exhaust Flexible Pipe (309-00B Exhaust System - 3.0L EcoBoost, Removal and Installation).
   Refer to: Exhaust Flexible Pipe (309-00C Exhaust System - 3.3L Duratec-V6, Removal and Installation).
   Refer to: Exhaust Flexible Pipe (309-00D Exhaust System - 3.3L Duratec-V6 – Hybrid (BP), Removal and Installation).
   

1. Install the rear driveshaft.
   Refer to: Rear Driveshaft (205-01 Driveshaft, Removal and Installation).