Ford D5AZ-7052-A Seal Assembly - Oil

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To perform the fuel pressure test, obtain a fuel pressure gauge and adapter set (fuel line fittings). After relieving the fuel pressure, lay a shop towel over any fuel connection to be disassembled to absorb the residual fuel. For the preliminary inspection, check the fuel system's delivery by listening at the fuel filler opening while an assistant turns the ignition key to the On position (engine not running). If no sound is heard, check the fuel pump fuse, relay, and circuit. If there's still no sound, there may be a problem in the fuel pump circuit or a faulty fuel pump. Check for battery voltage to the fuel pump relay connector and power relay connector. If present, have the relays tested at a qualified automotive repair shop. If no voltage is present, check the fuses and wiring circuit. For the operating pressure check, attach the fuel pressure gauge to the test port and activate the fuel pump without starting the engine. Note the fuel pressure and measure it again with the engine idling. Detach the vacuum hose from the fuel pressure regulator to check for an increase in pressure. If pressure is too high or low, inspect and replace components accordingly. For fuel pump replacement, remove the fuel pump/sending unit assembly from the vehicle carefully and install a new rubber gasket during reassembly. Adjust the angle and travel distance if the float arm and float wire loop were damaged during removal and installation. To replace the extension housing oil seal on 2WD models, raise the vehicle on jackstands, remove the driveshaft, flange/yoke nut, and washer, then remove the dust shield. Carefully pry out the old oil seal and bushing, using a special removal tool if needed. Install the new oil seal, reinstall the dust shield, and reassemble the driveshaft, flange/yoke, and nut. Lubricate the splines and driveshaft sleeve yoke, then install the driveshaft and lower the vehicle.

To perform the fuel pressure test, obtain a fuel pressure gauge and adapter set (fuel line fittings). After relieving the fuel pressure, lay a shop towel over any fuel connection to be disassembled to absorb the residual fuel. For the preliminary inspection, check the fuel system's delivery by listening at the fuel filler opening while an assistant turns the ignition key to the On position (engine not running). If no sound is heard, check the fuel pump fuse, relay, and circuit. If there's still no sound, there may be a problem in the fuel pump circuit or a faulty fuel pump. Check for battery voltage to the fuel pump relay connector and power relay connector. If present, have the relays tested at a qualified automotive repair shop. If no voltage is present, check the fuses and wiring circuit. For the operating pressure check, attach the fuel pressure gauge to the test port and activate the fuel pump without starting the engine. Note the fuel pressure and measure it again with the engine idling. Detach the vacuum hose from the fuel pressure regulator to check for an increase in pressure. If pressure is too high or low, inspect and replace components accordingly. For fuel pump replacement, remove the fuel pump/sending unit assembly from the vehicle carefully and install a new rubber gasket during reassembly. Adjust the angle and travel distance if the float arm and float wire loop were damaged during removal and installation. To replace the extension housing oil seal on 2WD models, raise the vehicle on jackstands, remove the driveshaft, flange/yoke nut, and washer, then remove the dust shield. Carefully pry out the old oil seal and bushing, using a special removal tool if needed. Install the new oil seal, reinstall the dust shield, and reassemble the driveshaft, flange/yoke, and nut. Lubricate the splines and driveshaft sleeve yoke, then install the driveshaft and lower the vehicle.

Raise the vehicle and support it securely on jack stands, ensuring that if equipped with Automatic Ride Control (ARC), the air suspension switch is turned to the OFF position to prevent damage to the system components. Place a drain pan under the extension housing, as some transmission lubricant may drain out when the driveshaft slip joint is withdrawn. Remove the driveshaft. Use a seal removal tool to take out the oil seal from the end of the extension housing, being cautious not to damage the housing if using a thin blade screwdriver or chisel instead. Inspect the sealing surface on the driveshaft slip joint for any scoring or burrs that could damage the new oil seal, and replace the yoke if it is damaged. Check the extension housing bore for burrs and remove them with emery cloth or medium grit wet-and-dry sandpaper, then clean the bore with a cloth dipped in solvent. Apply silicone sealant to the outside diameter of the oil seal and multipurpose grease to the seal lip. Using a seal driver, large socket, or section of pipe, install a new oil seal, ensuring it is completely seated and square to the housing. Install the driveshaft, lower the vehicle, and check the transmission lubricant level, topping up if necessary.

After removing the oil seal, inspect the oil seal contact surface on the case for any damage and clean it.

Inspect for scoring or burrs and remove them with emery cloth or fine sandpaper.

Carefully pry and pull on the outer curved lip of the oil seal and remove it from the transfer case.

Refill the transfer case lubricant.

Install the driveshaft.

Inspect the oil seal contact surface on the universal joint yoke for scoring or burrs that may damage the new oil seal. If the yoke is damaged in any way, replace it.

The final steps after replacing the oil seal are to install the front driveshaft, refill the transfer case lubricant, and lower the vehicle. If necessary, shift out of 4WD mode before returning the vehicle to normal service.

Slip them over the output shaft and carefully past the new seal until it bottoms.

To assure proper positioning during assembly.

The output shaft yoke washer, rubber seal, and the yoke.

Position the new seal to the output housing and using an appropriate driver, such as the Output Shaft Seal Replacer T83T-7065-B and Driver Handle TBOT-4000-W, press the seal into the housing until fully seated.

Check and adjust the transmission fluid level using Ford manual transmission lube D8DZ-19C547-A (ESP-M2C83-C) or equivalent.

Install the front yoke or rear flange onto the splines, then install the rubber seal, steel washer, and a new nut (snap-ring on the front yoke on later models). Tighten the nut to the torque.