I'm about to pull out the transfer case of my 2003 F150 Supercrew to replace the input seal and was just wondering if anyone has some good advice for the procedure or maybe a picture tutorial. I have the Hayes manual but it is very vague on the removal and installation of the transfer case itself. Any help would be greatly appreciated!

 

Once you drop the two drive shafts, there are only 5 to 7 bolts that hold the t-case to the transmission. The t-case is VERY heavy so make sure you have a jack under it. Remove the speedo cable on the upperside of the t-case, and unplug the power line from the harness. The t-case fluid is separate from the transmission but you'll need a gasket for the housing that separates them anyway. Inside there is a trans seal and a t-case seal. You should change both. They can be removed by prying them out with a heavy bent pick and the reinstalled with a piece of pipe or very large socket. Good luck.

 

Thank you!

 

Don't use cork, it will leak, instead use some heavy paper or thin cardboard.


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Thanks for the heads up!

 

Can RTV work for this as well?

 

Lite coat on both sides of the gasket material wouldn't be a bad idea.

Or if you get Ultra Gray let it skin a little bit and you won't need any gasket material, just follow the instructions on the package.


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I'll go ahead and take pictures of my progress and post a tutorial for anyone else that needs help with this.

 

The torsion keys are rusted solid on the torsion bars so I'd going to attempt to do the repair with the transfer case still under the truck.. This should be fun.

 

I'm faced with the same job on my '01 F150 Supercrew. Just curious how your job turned out. Were you able to do this with the transfer case under the vehicle? I'm assuming both the trans seal and the transfer case input seal can be replaced with no disassembly of the t-case or trans? Just want to know what I'm getting into. Anyone with knowledge of this please reply.