Lincoln Aviator 2020-2025 Service Manual / Powertrain / Automatic Transmission / Transfer Case / Removal and Installation - Transfer Case Rear Seal

Lincoln Aviator: 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

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

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

Drain the transfer case.
Refer to: Transfer Case Draining and Filling (307-07B Transfer Case, General Procedures).

Remove the exhaust flexible pipe.
Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Exhaust Flexible Pipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
Refer to: Exhaust Flexible Pipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).

Remove the muffler and tailpipe.
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Muffler and Tailpipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
Refer to: Muffler and Tailpipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).

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.

Remove and discard the flange nut washer.

Remove and discard the flange nut seal.

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

Remove and discard the transfer case rear output shaft seal.

Installation

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

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

Install the transfer case output flange.

Install the flange nut seal.

Install the flange nut washer.

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)

Refill the transfer case.
Refer to: Transfer Case Draining and Filling (307-07B Transfer Case, General Procedures).

Install the muffler and tailpipe.
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Muffler and Tailpipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Muffler and Tailpipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
Refer to: Muffler and Tailpipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).

Install the exhaust flexible pipe.
Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Exhaust Flexible Pipe (309-00A Exhaust System - 3.0L EcoBoost, Removal and Installation).
Refer to: Exhaust Flexible Pipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).
Refer to: Exhaust Flexible Pipe - Plug-In Hybrid Electric Vehicle (PHEV) (309-00B Exhaust System - 3.0L EcoBoost – Hybrid (BQ), Removal and Installation).

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

Removal and Installation - Transfer Case Input Shaft Seal

Special Tool(s) / General Equipment 205-1018Installation Tube 308-943Installer, Input Seal Removal With the vehicle in NEUTRAL, position it on a hoist...

Removal - Transfer Case

With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting (100-02 Jacking and Lifting, Description and Operation). If equipped, remove the transfer case heat shield...

Other information:

Lincoln Aviator 2020-2025 Owners Manual: Getting the Services You Need

Warranty repairs to your vehicle must be performed by an authorized dealer. While any authorized dealer handling your vehicle line provides warranty service, we recommend you return to your selling authorized dealer who wants to ensure your continued satisfaction...

Lincoln Aviator 2020-2025 Owners Manual: Inspecting Your Tires and Wheel Valve Stems

Periodically inspect the tire treads for uneven or excessive wear and remove objects such as stones, nails or glass that may be wedged in the tread grooves. Check the tire and valve stems for holes, cracks, or cuts that may permit air leakage and repair or replace the tire and replace the valve stem...

Activating Intelligent Access

The intelligent access key must be within 3 ft (1 m) of the door or luggage compartment you intend to lock or unlock.

At a Door

Electronic door handles are on each door. Gently depress the switch inside the exterior door handle to unlock and open the door. An unlock symbol illuminates on the door window trim indicating your vehicle is unlocked.

Lincoln Aviator. Activating Intelligent Access