Section 07-07B: Transfer Case, Manual Shift
1996 F-150, F-350 with 137-Inch Wheelbase, Chassis Cab with E4OD Transmission and Bronco Workshop Manual
REMOVAL AND INSTALLATION

Oil Seal

Output Shaft, Front and Rear

Refer to Transfer Case, Mechanical Shift in the Disassembly and Assembly portion of this section.

Output Shaft, Rear Extension Housing (Slip Spline Type)

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Extension Housing Seal ReplacerT61L-7657-B

Removal

  1. Raise the vehicle on a hoist and position suitable safety stands under vehicle.

  1. Disconnect driveshaft from rear of transfer case (7A195). Refer to Section 05-01.





  1. With a screwdriver, pry the yoke to flange seal (7B215) from the bearing retainer. Discard the yoke to flange seal.

Installation

  1. Position the yoke to flange seal in the retainer so the notch on the yoke to flange seal faces upward and the drain hole in the rubber dust boot faces downward. Drive the yoke to flange seal in the retainer using Extension Housing Seal Replacer T61L-7657-B.





  1. Install driveshaft. Refer to Section 05-01.

  1. Remove safety stands and lower vehicle.

Output Yoke, Front (All) and Output Flange, Rear (Bronco)

Removal

  1. Raise the vehicle on a hoist and position suitable safety stands under vehicle.

  1. Remove the rear or front driveshaft from the transfer case output shaft case yoke (7B214). Wire the driveshaft(s) out of the way. Refer to Section 05-01.

  1. Remove the output shaft case yoke by removing the 32mm shaft nut (7045), output shaft yoke washer (7B368) and oil seal (7052) from the rear or front output shaft and remove the case yokes.

  1. Remove the yoke to flange seal from the rear output housing bore with a screwdriver.

Installation

  1. Make sure the output housing bore and face are free from nicks and burrs. Position the yoke to flange seal into the front or rear output housing bore, making sure that the yoke to flange seal is not cocked in the bore. Drive the yoke to flange seal into the bore with a suitable output shaft seal replacer.

  1. Install the case yoke, oil seal, output shaft yoke washer and shaft nut on the front or rear output shafts. Tighten the nut to 203-244 Nm (150-180 lb-ft) front; 163-203 Nm (120-150 lb-ft) rear.

  1. Connect the front or rear driveshaft to the transfer case output shaft case yoke. Refer to Section 05-01.

  1. Check lubricant level. Adjust as required.

  1. Remove safety stands and lower the vehicle from the hoist.