Lincoln Aviator 2020-2026 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 2020-2026 Service Manual: Description and Operation - Identification Codes

VIN VIN Locator The VIN is a 17-digit combination of letters and numbers. The VIN is stamped on a metal tab riveted to the instrument panel, top upper left of the dash. The VIN is also found on the VC label. If the VIN plate requires replacement, authorized dealers must contact their respective regional office...

Lincoln Aviator 2020-2026 Service Manual: Diagnosis and Testing - Charging System

Diagnostic Trouble Code (DTC) Chart Diagnostics in this manual assume a certain skill level and knowledge of Ford-specific diagnostic practices. REFER to: Diagnostic Methods (100-00 General Information, Description and Operation). Diagnostic Trouble Code Chart Module DTC Description Action BCM B11DB:02 Battery Monitoring Module "A": General Signal Failure GO to Pinpoint Test F BCM B11DB:08 Battery Monitoring Module "A": Bus Signal/Message Failures GO to Pinpoint Test F BCM B11DB:09 Battery Monitoring Module "A": Component Failures GO to Pinpoint Test F BCM B11DB:11 Battery Monitoring Module "A": Circuit Short To Ground GO to Pinpoint Test F BCM B11DB:49 Battery Monitoring Module "A": Internal Electronic Failure GO to Pinpoint Test I BCM B11DB:55 Battery Monitoring Module "A": Not Configured GO to Pinpoint Test J BCM B1489:11 Battery Monitoring System (BMS) Sensor Power: Circuit Short To Ground GO to Pinpoint Test F PCM P0562:00 System Voltage Low: No Sub Type Information GO to Pinpoint Test B PCM P0563:00 System Voltage High: No Sub Type Information GO to Pinpoint Test A PCM P065B:00 Generator "A" Control Circuit Range/Performance: No Sub Type Information GO to Pinpoint Test B PCM P065C:00 Generator "A" Mechanical Performance: No Sub Type Information GO to Pinpoint Test B PCM P0A3B:00 Generator "A" Over Temperature: No Sub Type Information GO to Pinpoint Test K PCM P0A5A:00 Generator Current Sensor Circuit Range/Performance: No Sub Type Information GO to Pinpoint Test E PCM P0A5B:00 Generator Current Sensor Circuit Low: No Sub Type Information GO to Pinpoint Test E PCM P0A5C:00 Generator Current Sensor Circuit High: No Sub Type Information GO to Pinpoint Test E PCM U012D:00 Lost Communication With Generator "A" Control Module: No Sub Type Information GO to Pinpoint Test G PCM U042E:00 Invalid Data Received From Generator "A" Control Module: No Sub Type Information GO to Pinpoint Test G Inspection and Verification Verify the customer concern by operating the charging system...

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