Replacing Transfer Case Gasket

[DSteele41]

Just Replaced Engine and Transmission in 03 Sport Trac 4WD

What is the Process of Replacing Gasket ?

(The Gasket on there is Leaking ; It is a Traced Gasket from a roll of Gasket; I know ...I Know... O'Reillys didn't have the Gasket and me and a buddy were ready to wrap up Job after 2 months of full weekends doing both jobs)

Will I have to Drain All Tranny Fluid ?
(just spent over $100.00 on OEM Mercon Fluid)

Is it as simple as unbolting both drive shafts and unbolting Transfer case from Transmission ?

Thanks in Advance

DSteele41

 

[imp]

Just Replaced Engine and Transmission in 03 Sport Trac 4WD

What is the Process of Replacing Gasket ?

(The Gasket on there is Leaking ; It is a Traced Gasket from a roll of Gasket; I know ...I Know... O'Reillys didn't have the Gasket and me and a buddy were ready to wrap up Job after 2 months of full weekends doing both jobs)

Will I have to Drain All Tranny Fluid ?
(just spent over $100.00 on OEM Mercon Fluid)

Is it as simple as unbolting both drive shafts and unbolting Transfer case from Transmission ?

Thanks in Advance

DSteele41

View attachment 325128

Not sure about Sport Trac; my '04 XLS has an oil seal on transmission output shaft, oil seal on transfer case input shaft, and it appears that a leak between the two MUST mean a leaking oil seal, gasket or no gasket.

 

[DSteele41]

Not sure about Sport Trac; my '04 XLS has an oil seal on transmission output shaft, oil seal on transfer case input shaft, and it appears that a leak between the two MUST mean a leaking oil seal, gasket or no gasket.

This Leak is 100% coming from the Gasket in Between Transfer Case and End of Transmission (Park Pawl).

@410Fortune @DILLARD000

Could you guys possibly weigh in on Process of Replacing this Gasket

 

[imp]

This Leak is 100% coming from the Gasket in Between Transfer Case and End of Transmission (Park Pawl).

@410Fortune @DILLARD000

Could you guys possibly weigh in on Process of Replacing this Gasket

Look closely at this adaptor:

The cavity between the transmission and transfer case has a WEEP HOLE placed in it at the factory. This is how my '04 is made. No gasket, unless dust is a consideration, you can include one if you like (I siliconed it). Any leakage HAS to be seal leakage, either trans. fluid or transfer case. I noted that the t-case input shaft seal had 2 LIPS, to exclude leaked transmission fluid from getting into the t-case past it's sealing lip. The right side faces the t-case interior. This is not to say ALL explorers are this way.

 

[RangerX]

Which trans and transfer case models does an 03 Sport Trac have?

 

[imp]

Which trans and transfer case models does an 03 Sport Trac have?

That's what I've been wondering.........

 

[410Fortune]

03 trac uses 5r55e and 1354 non control trac
The 5r55e has the second OSS sensor in the tailhousing

All Sport tracs 01-05 use 4.0 Sohc and 5r55e auto with the e shift 1354 t case
SOME rare tracs had the M5od manual transmission

 

[DSteele41]

@

Which trans and transfer case models does an 03 Sport Trac have?

5R55E on Transmission Not sure of Model of Transfer Case ... I didn't Replace it ; I'll look it up though

 

[DSteele41]

03 trac uses 5r55e and 1354 non control trac
The 5r55e has the second OSS sensor in the tailhousing

All Sport tracs 01-05 use 4.0 Sohc and 5r55e auto with the e shift 1354 t case
SOME rare tracs had the M5od manual transmission

@410Fortune

Got it 134 Transfer Case !

 

[RangerX]

I’ve separated and removed a 1354 from a manual trans on two Rangers and there was no real fluid loss. Trans is sealed and tcase is sealed, with a dry gasket between.
No idea on an auto trans though.

 

[DSteele41]

I’ve separated and removed a 1354 from a manual trans on two Rangers and there was no real fluid loss. Trans is sealed and tcase is sealed, with a dry gasket between.
No idea on an auto trans though.

I replaced gasket today ....used RTV on both sides of it ....Leak Gone.