Ford Excursion :: Transfer Case Input / Front Seal Replacement
Mar 17, 2016
Noticed some fluid on the bottom of the Ex a few months ago and have been watching it since. Drained and refilled with the XL-12 fluid at the time and based on what I can see the likely culprit is the input seal on the transfer case. I have searched high and low both here and via the almighty google with little info to be found. Is it simply remove transfer case, replace input seal, reseal case connection, and refill?
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I had my truck at the shop today and it was determined that the transfer case front driveshaft seal is leaking and the gasket between the transmission and transfer case has also failed. The shop wants a reasonable amount to fix it but they need the truck for 2-3 days. It doesn't appear to be that difficult of a job to remove the transfer case. Am I missing something? Dropping off the truck and leaving it for a few days is the difficult portion......if they could do it in a day I'd just pay them and be done with it. So my thought was to pull it and just drop it off so they can replace the seals and fix any other issues.
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I found that my transmission was low on oil but couldn't find a leak. What I did find is that the seal in the transfer case was letting trans fluid transfer into it and then it would leak out the out put seal. I purchased the new seal and gasket and repaired it myself in about 3 hours. I removed the rear drive shaft and removed the front drive shaft from the transfer case alone or you can take it out completely if you want.
Drained transfer case unplugged wiring and one vacuum line. Unbloted from trans and removed using trans jack. The bolts are not the easiest to get to. i used a 3/8 ratchet to break them loose then used a stubby 3/8 to get them out because they are around 2 inches long. Once down I had to jack up the truck to get it out from under it. I removed the old seal and installed new one cleaned everything up and installed with a new gasket.
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I got a 97 f150 4x4, 4.6 and I had the shop replace the seal 3 times and it's still leaking, the seal where the driveshaft goes into the t case, I call it the slip yoke seal, they said the bushing inside looks good, there doesn't seem to be a whole lot of play in the driveshaft, it doesn't seem to leak a whole lot, I'm about ready to just forget about it and just run it, they put a seal from oreillys in, it seem to be leaking out of the bottom hole on the seal...
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I just changed transfer case fluid on my father's F-350 for the first time in 13 years. (over 230k). Removed fill plug first and fluid gushed out of the fill hole unexpectedly. Did not have catch pan ready, so made a mess. I thought it was just over filled form the factory, but too much was coming out to be simple overfill. Almost 2 qt came out of the fill plug.
Did some google search and found many Ford trucks have failed transmission output shaft seal and transmission fluid leaks out to transfer case, causing transfer case to overfill. I am yet to check transmission fluid level, but considering how much came out of it that probably is the case.
Now, how bad of the problem this really is? Will overfilled transfer case cause some serious problem? 4x4 is rarely used (once or twice a year in winter) on this truck and from what I understand transfer case doesn't really do anything in 2WD other than just passing output from transmission through.
There are no fluid leaking outside and repairing the seal would be a too much of work for me.
Also changed rear differential fluid for the first time and I was surprised how clean the fluid was. There were thin layer of black sticky residue (sludge?) covering everything, but the fluid itself looked clean and no visible metal shavings. I guess that is why Ford said it does not require change under normal condition.
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Looking at another Ex but the owner says the transfer case does not engage. Says it can be locked into 4X4 by crawling under it and engaging it manually by removing a motor [Servo motor ?] Does this mean I would need a new transfer case or just the servo motor ? I know mine did the same thing last winter. It would go into 4X4 and then pop out.
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2003 ex 6.0 limited....300000 miles ...Automatic.Merry Christmas to all.My Transfer case will not shift into 4wd . Dash light for 4wd high and low works .I get no power to transfer case 2pin connector when key turned on.Also fuses 19,27,31,33,34,45,111 are all good when checked with meter.I also swapped 2 relays in engine compartment and no change.4 WD Switch on dash has power on Green/red wire I think it is for dash light and not for operation.
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Swapped out my transfer case since mine was detonated and now my tranny is running hotter? Drove in town for about 10-15 minutes and noticed my temps climbing and once it got to 180 it felt like it was slipping when moving from a full stop. i went home and parked it. Checked my fluid level and it looked a little low so topped it off while running and went through gears to make sure it was good. Drove again and it still went up to 180 in 10-15 minutes in town driving. Before we swapped the transfer case it was driving fine and went on a road trip 6 hour drive and felt fine. I bought the excursion and it supposedly had a new tranny in it.
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The dang thing leaks from the fill plug, I been reading about using liquid teflon on it.
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I had sold my Explorers but just picked up a 2000 Excursion V10 plow truck. It has been hacked and slashed I find cut wires under the dash and hood. I have tried everything to get the 4x4 to engage and no luck. It is used just for my driveway no road driving...
So question is: Can I engage the 4x4 at the transfer case so it will go, and stay in 4 wheel drive. If so do I take the shift motor off or does that big bolt by the motor do anything.
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Do we need to drain the fluid to change the transfer case motor?
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I have an 04 Limited, 6.0 PSD, 4x4 which I need to replace the front inner axle seals, the right side is leaking out the shaft. I have watched a couple of YouTube videos on how it is done but would like to get some first hand knowledge and recommendations.
First, how important is it to check the backlash before beginning the removal of the gear assembly? Do I need to remove the pinion gear as well or just the gear assembly?
How difficult is it to get everything back on place once the seals are replaced? I have not done this type of repair before and am concerned I might miss something.
I am planning to replace all the ball joints at this time also, this was the primary reason for this maintenance in the first place.
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Having problems. Transfer case broke in half, I think it is because of the auto free wheeling hubs. Is it possible to manual hubs on it?
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My TC motor picked today of course with the snow to go bad. Luckily I hobbled to advance right as they were about to close and got one. I laid in the snow and changed it. Needless to say I got soaked beyond belief. Anyways now it changes in and out well but still seems way to loose in the rear. Not sure if something else is malfunctioning or if these things are like that. Right now I don't feel nearly as safe as I did in my expedition and that was without even using 4hi or low just the A4WD. The excursion is sliding everywhere. My tires have great tread but are highway tires so maybe that's the issue. They are Dura Grapplers. I'm going to try throwing some weight in the rear to maybe gain some traction.
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Driving on my way home, my Excursion began vibrating and bang the transfer case broke in half. question will a 2000 f250 tcase swap with mine?
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My excursion has not been engaging the transfer case when the switch is turned on. I have ohmed the switch and also tried a known good switch from another superduty. I can get everything to work properly with a snap on MODIS by performing function tests.
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I'm replacing my clutch components in my 89 Ranger with an M5OD transmission. While I'm doing it I'm going to replace the input shaft seal on the transmission. I'm looking for the torque specs for the housing that holds the seal.
Also, should there be any play on the input shaft? My transmission has never made any noise but I noticed some slight play in the shaft.
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On my 2007 f150 5.4 last week i changed out the driveshaft and it smoothed things out. This past weekend I dropped the transfer case oil and refilled it with motorcraft transfer case oil as per ford but now the front end seems to shake more than before. It just seems to come through the steering wheel but the wheel seems tight almost like a death wobble with solid front axles except obviously this truck doesn't have that. There are no leaks and I filled it up to the top fill hole with between 1.5 to 2 liters of oil until it started running out. I should also mention that when i went to check the level it was overfull on the top plug but it was that way for the last 90,000 km or so.
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I have noticed a few drips coming from the rear axle input shaft where the drive shaft connects. It has only done it once and there is no residue on the trailer hitch so I know it didn't dump everything on the road. If change this seal, how difficult is it and do you have any information which might make it easier.
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Couple weeks ago found some oil drops in the drive way so I got Underneath to see this disappointment. Hope the pictures come through for you all to see. She's been in the shop since Monday.
front crank case seal gone bad! what a mess.
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Made a short run to get lumber yesterday and when I got home the truck smelled hot I checked it out and found a transmission oil leak at the rear of the transmission in front of the transfer case. can not really see what is leaking only has 22,000 miles. What may have happen. 2011 F250 4x4 6.7....
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