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Discussion Starter #1
Last Sunday I decided to change the ATF in my transfer case. Well after finally getting the stripped 10mm square fill plug out I got a shower of ATF fluid. Luckily I had a bucket handy and held it under the fill hole. Now I was NOT ready for fluid to come out of the FILL hole. When the fluid finally stopped I took the drain plug out and drained the rest of the fluid. When all said and done I had about 6-7 quarts of ATF in my bucket.:doh0715:

Now after searching and reading I figure I have a bad seal between the AOD trans and the BW1356. I have found a replacement seal for the TC. But is there a rear seal on the AOD trans? If so can some one give me a part number? Also if you have a part number for the TC seal that would be great as well. I have looked and there are so many seals that my head is spinning.

Also is there anything else that could cause the ATF fluid to enter the TC? I have read about the vent in the TC blowing out the seals if it is plugged. So I will be cleaning that out when I drop the TC.

Any other thoughts from anyone that has had this happen would be great. I hope to get this taken care of A.S.A.P.!!

Thanks All!:thumbup
 

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The only way to get extra fluid in there would be through the tranny. Have you had to add fluid to the tranny? It should be called transmission output shaft seal. Go to napa. When they pull it up there should be an exploded view of the tranny with seals. Or call a local tranny shop. They should give u the number
 

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yo C,

TSB 97-12-13 TRANSMISSION - C6, E4OD, AOD, 4R70W - LOW TRANSMISSION FLUID LEVEL AND/OR SHIFT AND/OR ENGAGEMENT CONCERNS - 4X4 AND AWD VEHICLES ONLY

1987-96 BRONCO 1987-97 F-150, F-250, F-350
1996-97 EXPLORER, 1997 EXPEDITION, MOUNTAINEER
This TSB article is being republished in its entirety to include 1997 model year vehicles.

ISSUE: The transmission may have low fluid level and/or may have either a shift concern and/or an engagement concern. This may be caused by transmission fluid leaking from the transmission into the transfer case through the transfer case input seal.

ACTION: Replace the transfer case input seal. The new seal should reduce the possibility of fluid leaking from the transmission into the transfer case. Refer to the following Service Procedure for details.

SERVICE PROCEDURE:
1. Check the transmission fluid level. It the transmission fluid level is low and there are no visible signs of a leak, check the transfer case fluid level. The level of fluid in the transfer case should be just below the fill plug hole.
2. If the transfer case fluid level is overfull and the transmission fluid is not burnt, remove the transfer case from the vehicle following the procedure outlined in the appropriate model/year Service Manual.
3. Remove the transfer case input seal. Clean the seal bore in the transfer case.
4. Install a new Transfer Case Input Seal (F77Z-7B215-AA)
5. If the transmission fluid is burnt, repair the transmission as required and then replace the transfer case seal as outlined in Step 3.

PART NUMBER PART NAME
F77Z-7B215-AA Transfer case Input Seal
Replace Transfer Case 1.6 Hrs
1987-96 F-150-350, Bronco


Fluid Level Low, Low Transmission Fluid Level And Or Shift And Or Engagement Concerns TSB 97-12-13 for 87-96 Bronco & many others; "...Just an update, I used the part #F77Z-7B215-AA from the input shaft seal TSB and used it to cross reference new seals from a few different auto parts stores. All of them produced a seal same as the one I had, just different manufacturers. So far so good I used a paper gasket and some RTV at the intermediate tailhousing because mine had them there, a few people said I could get away with just some RTV, but it was only $6 so I sprung for the gasket. No leaks so far from the tailshaft or from the input seal, I will periodically check it over the next couple of months to make sure. One more piece of the puzzle done, next up is the fuel pump. Here is the original seal removed, I damaged it getting it out..." miesk5 Note, see his pics
Source: by slim724 at FSB

For other AOD concerns in future read through this AOD Description & Operation, Identification Tag, Parts Break-Out Diagram w/Nomenclature, Seals, Rings & Gaskets Locator, Throttle Valve (TV) System, Transmission Shift Patterns, Main Components & Functions, Diagnosis & Testing, In-Vehicle Service, R&R, Cleaning & Inspection, Specifications, & Special Service Tools/Equipment
This book costs $35.00, so dnld & save
other leaks @ EXT Housing Bushing & Real Seal on page 21
 

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yo,


Transfer Case, Manual Shift, 13-56
Item Part Number Description
1 7045 Shaft Nut
2 7B368 Output Shaft Yoke Washer
3 7052 Oil Seal
4 7B215 Yoke to Flange Seal
5 � Extension (Rear Spline)
Cap, Bearing (Rear Yoke/Flange) (Serviced As Part of 7085 Assembly)
6 7085 Extension Assembly
(Rear Spline) Cap Assembly, Bearing (Rear Yoke/Flange)
7 7A443 Bolt and Washer Assembly (1989 and Later)
8 � Flange (Rear Flange) (Serviced As Part of 7B214 Assembly)
9 7917 Ring, Snap
10 7025 Bearing
11 7917 Ring, Snap
12 7100 Shift Collar Hub
13 7127 Caged Needle Bearing
14 7A010 Plug, Pipe
15 7917 Ring, Retaining
16 7D164 Lockup Hub
17 7D126 Spring, Lockup
18 7106 Lockup Collar
19 7177 Sprocket, Drive
20 7A210 Hose
21 382486-S Clamp, Hose
22 7A291 Transfer Housing to Case Bolt
23 7E215 Retainer, Pump
24 7A152 Cover, Pump
25 7A149 Housing, Pump
26 7A250 Pin, Pump
27 7A205 Spring, Pump Pin
28 7061 Output Shaft
29 7100 Shift Collar Hub
30 7A398 Front Planet
31 7C122 Ring, Retaining
32 7A153 Ring Gear
33 7A098 Filter, Oil
34 � Gear, PTO (with PTO Only)
35 7917 Ring, Retaining
36 � Ring, Retaining
(Part of 7B215)
37 7166 Case Deflector Gasket (with PTO Only)
38 7165 Transfer Case Cover (with PTO Only)
39 381673-S Bolt (with PTO Only)
40 7034 Vent
41 7E440 4WD Indicator Switch
42 � Setscrew (Part of 7E440)
43 � Fork, Reduction (Serviced As Part of 7289 Assembly)
44 � Facing, Shift Fork (Serviced As Part of 7289 Assembly)
45 7289 Ford Assembly Reduction
46 7235 Roller, Cam (Service As Part of 7289 Assembly)
47 � Pin (Part of 7289)
48 7C430 Facing, Shift Fork
49 � Retainer (Serviced As Part of 7289 Assembly)
50 7289 Fork Assembly, Shift, 2W-4W
51 7240 Shift Rail
52 7219 Shift Fork Spring
53 7C349 Spring, Detent
54 7C191 Bushing, Detent
55 7F063 Cam, Shift
56 7288 Shifter Shaft Seal
57 7B106 Lever, Shaft and Pin Assembly
58 7005 Case
59 � Pin Dowel (Part of 7005)
60 7L027 Oil Pan Magnet
61 7917 Ring, Retaining
62 7061 Output Shaft
63 7177 Sprocket, Driven
64 7119 Thrust Washer
65 7917 Ring, Retaining
66 7A029 Chain, Drive
67 � Yoke (Serviced As Part of 7B214 Assembly)
 

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I am with Miesk. I dont think in the 4x4 application that the C6 has a rear seal. It bolts directly to the TC and uses the input seal of the TC to keep the fluids seperate. Even the 2x4 tranny's have a type of rear uotput seal , but , it requires the slip yoke to be in place in order for it to work.

So yes, if the TC has more than 2 qts of fluid in it, it is sharing fluid with the tranny which isnt good. The way the fill plug is set up on the TC you cant get too much fluid in it W/O laying the TC on its side and filling it up.

Now, if you have an excessivley worn input seal there is probably excessive wear on the input bearing which is allowing endplay. Might want to consider putting a bearing/seal kit in as well as a pump kit. The parts will set you back about $200.00.
 

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When i rebuilt my np205(different, but probably still applies) I put 2 input seals in it, one facing away from the other. This way it keeps the fluid in the t-case and keeys the trans fluid from getting into the t-case thru the adapter
 

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Discussion Starter #7
Well I talked to a local trans shop today. They said to check the rear sleeve on the trans. If that is worn it can cause the seals to fail. If the sleeve is bad can this be changed externally?

Also they said there is a external housing seal on the trans as well as the front seal on the transfer case.
 

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Well I talked to a local trans shop today. They said to check the rear sleeve on the trans. If that is worn it can cause the seals to fail. If the sleeve is bad can this be changed externally?

Also they said there is a external housing seal on the trans as well as the front seal on the transfer case.
yo,
Yep.. see my first reply

For other AOD concerns in future read through this AOD Description & Operation, Identification Tag, Parts Break-Out Diagram w/Nomenclature, Seals, Rings & Gaskets Locator, Throttle Valve (TV) System, Transmission Shift Patterns, Main Components & Functions, Diagnosis & Testing, In-Vehicle Service, R&R, Cleaning & Inspection, Specifications, & Special Service Tools/Equipment
This book costs $35.00, so dnld & save
other leaks @ EXT Housing Bushing & Real Seal on page 21
 

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Discussion Starter #10
Thanks miesk5! You always come through!!:beer
 

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yw,'
GL!

Also,onspect real main seal... consider replacing due to leaks or age
 

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Discussion Starter #12
Has anyone had to use a repair sleeve on the rear extension?

If so how hard is this to install?

The trans guy said to make sure and check the condition of the sleeve. A bad sleeve would cause the seals to fail.
 

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Discussion Starter #13

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Discussion Starter #14
Has anyone had to use a repair sleeve on the rear extension?

If so how hard is this to install?

The trans guy said to make sure and check the condition of the sleeve. A bad sleeve would cause the seals to fail.
Anyone??
 
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