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

Ford Explorer 2020-2025 Service Manual / Powertrain / Automatic Transmission / 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).

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

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    Categories

    Driver and Passenger Airbags

    WARNING: Do not place your arms on the airbag cover or through the steering wheel. Failure to follow this instruction could result in personal injury.

    WARNING: Keep the areas in front of the airbags free from obstruction. Do not affix anything to or over the airbag covers. Objects could become projectiles during airbag deployment or in a sudden stop. Failure to follow this instruction could result in personal injury or death.

    WARNING: Airbags can kill or injure a child in a child restraint. Never place a rear-facing child restraint in front of an active airbag. If you must use a forward-facing child restraint in the front seat, move the seat upon which the child restraint is installed all the way back.

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