1997 F-150 4x4 w/4.6
How hard is it to replace the output shaft seal? Just pop it out and press a new one in?

Please help!

Thanks

 

It's really easy. Buy a new $5 extension housing seal. SET EMERGENCY BRAKE. Unbolt and remove driveshaft. Carefully remove the seal( I had to buy a seal puller). make sure seating surface is clean. Pound the new one in. I used a coupler for 2inch PVC pipe with a small piece of playwood glued to the end to provide even pressure.

Note: I didnt totally read your post. I didnt realize you had the 4x4. Those directions were for my 99 2 wheel drive........oops.

 

Looks like the process is pretty much the same for 4 and 2 x's then. kristophers' steps are the same as what I did with my '00 4x. The PVC pipe is a nice trick to help puond the new one in. I found a PVC cap that was close enough diameter for me to just set it over the new seal and start tapping in. If you're careful enough you probably can gently pry the old out with a small screwdriver and tap the new one in with just a hammer by slowly working your way all the way around.

 

I found that mine didnt come out that easily. I had to give it a little motivation if you know what i mean. That seal was mutilated by the time i got it out

 

This topic is very timely, as I'm about to redo the seal on my 92 2wd. I'm not convinced that's where my leak is, but the guys at the quick oil change said it was, so no harm in trying it, I figure. The pvc cap idea for a press to push the new seal in is a good idea, I think I'll go and pick up a suitable one, I was going to cut something out of ply.

In terms of removal, I was figuring I might try and use a two-jaw gear puller, if you put a flat bar across the back of the extension you'll have something to push against, true, it won't pull it all the way, but if you get it that far, the rest of the way will probably be easy. One could probably make one of those pulling hammer things easily enough with some metal bar or strapping, and some threaded rod with a weight or large nut and washer slipped on it.

 

Check the DS yoke carefully. A lot of the time, when the seal goes, it's exacerbated by the yoke wearing a ring in itself. If this is the case, replacing just the seal won't help.

 

Hmm I feel somewhat 'shafted' - firstly, there is no sign of oil leaking at the seal, it all seems to be coming from the top access plate (where the shifter is) or the rear extention, probably the top plate. I do park in my very steep driveway which is a big part of the problem. Moreover, they didn't even give me the right seal, they gave me a flat seal which looks more like an engine seal, whereas what I have now is a tapered extended conical rubber thing - so clearly I don't have the Mazda gearbox (92 f150, 2wd 5.0 v8, 4 spd+OD)

Chances are I'll need to do my clutch sometime, so I guess I'll look at doing it them. I see there is an access plate from above where the gearshift is, but I'd have to remove the seat and the floor mat completely, which looks like a biggish job in itself, since it's a one-piece vinyl sort.

If I had to do the seal on the extension, that'd be the time to do it as well - anyone know what's involved? Does it just unbolt and slide off? I'm wondering if that's the overdrive part...?