-- New thread started because I hopped into the wrong thread. Sorry about that Bismic. --

I need some help. I have a 03 Excursion 6.0 that just developed a transmission leak between the transmission and transfer case. It appears to be the transmission because the transfer case fluid is at the top. I started to notice transmission fluid leaking in my driveway. I have not had any driving issues with the transmission but I am not driving until I correct the problem. If this is the rear transmission seal, how had is it to change this seal? Must I remove the spacer between the transfer case and 5r110 tranny? Any special tools needed? Any insights you have would help.

My temps have stayed at or below 150 if I recall. My fluid is slightly low in the transmission at about 134 operating temperature. The fluid is clean, red and has no burnt odor. My transfer case is topped off. Fluid ran out the fill plug when I removed it.

There is an aluminum square spacer than necks down. It is about 6" long between the transmission output on the excursion and the transfer case.

The leak I see is where that spacer meets the transfer case. I see enough for the fluid to leak onto the crossmember and to the driveway. I estimate that I have lost less than a 1/2 quart of fluid over a couple weeks.

 

The seal is part of the nut if I recall it right. I'll have to check the
workbook DVD for you to get the PDF file to post.

The adaptor is wet and the seal is between it and the transfer case.
You also have a gasket between the two units.

I'll double check this for you and post what I find. Right now all I have
access to is the 06 stuff.

Sean

6.0L Tech Folder

 

First, that is not a spacer - it is the extension housing used on fixed-yoke and 4X4 applications of the TorqShift® transmission. The output shaft seal and the nut come together in the package and must be replaced as a set. And on that note, the seal requires a seal driver, Ford part number 307-453 and the nut requires a special socket, Ford part number 307-458 which is a spanner socket of sorts. You WILL need it. Torque to 148 lb/ft. Lastly, there should not be any gasket between the transmission and the transfer case.

 

Thanks Keith and Yahiko. I have been scouring the net for this type of information. This information is very helpful.

 

2003 did have that gasket.

TK20255 Ford Transfer Case Adapter Gasket

Ford dropped it after 2004 and up.
The OP has an 03

Also I looked for and could not find the 100%
correct seal and tool. This is what you would be looking
at more or less when replacing the output shaft seal.



NOTE :
I have both the tool and a seal and if I can find them. I'll post the photo in
place of this one.

Sean

6.0L Tech Folder

 

Thanks Yahiko. This helps me understand the one piece nut/seal and tool required. I did not know there was a gasket between the trans extension and transfer case. Great info! Thanks again.

 

I picked some parts out of the box that the dead transmission is sitting in for
you. There are two parts to the seal in the housing the one that you screw in
place and the one you need the driver. The book has you using a special tool
to remove the old seal in the housing. It is for small places and will grip under
the edges of the seal to pull it. It's tool number 307-454 I stuck the shaft back
in so you can see how it looks when it installed.












































Sean

6.0L Tech Folder

 

Thanks Sean!