Transfer Oil Seal Replacement

Transfer Oil Seal Replacement

Special Tools Required

- Flange Holder 07XAB-0010101
- Driver Handle, 15 x 135L 07749-0010000
- Oil Seal Driver Attachment, 65 mm 07JAD-SH30100
NOTE: To prevent damage to the transfer housing, always use wood blocks or equivalent materials between the transfer housing and a vise.

1. Remove the transfer assembly Transfer Assembly Removal.

2. Remove the transfer cover (A) from the transfer housing (B).





3. Remove the transfer hypoid drive gear/shaft assembly (C).

4. Remove the O-ring (D) from the transfer cover.

5. Drain the transfer fluid (hypoid gear oil) from the transfer housing.

6. Cut the lock tab on the locknut using a chisel.






7. Secure the transfer housing (A) in a bench vise (B) with wood blocks.





8. Install the flange holder on the companion flange, then loosen the locknut.

9. Remove the flange holder.

10. Remove the locknut (A), the conical spring washer (B), the back-up ring (C), the O-ring (D), and the companion flange (E) from the transfer output shaft (hypoid gear) (F).






11. Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B), then remove the thrust washer (C) and the transfer spacer (D) from the transfer output shaft (hypoid gear).






12. Remove the oil seal (A) from the transfer housing (B).






13. Install a new oil seal flush with the transfer housing using the 15 x 135L driver handle and the 65 mm attachment.






14. Install the thrust washer (A) and a new transfer spacer (B) on the transfer output shaft (hypoid gear) (C) in the direction shown, and install them in the transfer housing (D).





15. Coat the threads of the locknut and the transfer output shaft (hypoid gear) with transfer fluid (hypoid gear oil).

16. Install the companion flange (A). Coat a new O-ring (B) with transfer fluid (hypoid gear oil), then install the O-ring, the back-up ring (C), a new conical spring washer (D), and a new locknut (E) on the transfer output shaft (hypoid gear) (F). Install the conical spring washer in the direction shown.






17. Secure the transfer housing (A) in a bench vise (B) with wood blocks.





18. Install the flange holder on the companion flange.

19. Tighten the locknut while measuring the starting torque of the transfer output shaft (hypoid gear) so the starting torque is within 1.15-1.71 Nm (11.7-17.4 kgf-cm, 10.2-15.1 lbf-in).









NOTE:

- Rotate the companion flange several turns to seat the tapered roller bearings, then measure the starting torque.
- If the starting torque exceeds 1.71 Nm (17.4 kgf-cm, 15.1 lbf-in), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the locknut loose.
- If the tightening torque exceeds 294 Nm (30.0 kg-m, 217 lb-ft), replace the transfer spacer and reassemble the parts.

20. Remove the flange holder.

21. Stake the locknut to a depth (A) at least 0.7 mm (0.03 in) using a 3.5 mm punch (B). Be careful not to make a crack on the locknut when staking.






22. Install the transfer hypoid drive gear/shaft assembly (A) in the transfer housing (B).





23. Install a new O-ring (C) on the transfer cover (D), then install the transfer cover on the transfer housing.

24. Remove the filler plug (A), then refill the transfer assembly with transfer fluid (hypoid gear oil). Use an SAE 90 viscosity hypoid gear oil, API classified GL4 or GL5 only.













25. Install the filler plug with a new sealing washer (B).

26. Check the transfer gear backlash and the total starting torque Transfer Assembly Inspection - Out-of-vehicle.

27. Install the transfer assembly Transfer Assembly Installation.