Seals and Gaskets: Service and Repair

Special Tools:

REMOVAL

WARNING: THE ELECTRICAL POWER SUPPLY TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR JACK STORAGE AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

1. With the vehicle in neutral, raise and support the vehicle.





2. Index the rear driveshaft yoke to the transfer case companion flange.





3. Index the rear driveshaft to driveshaft rear axle companion flange.





4. Remove the rear bolts and disconnect the rear driveshaft.





5. Separate the rear driveshaft from the transfer case.
1 Remove the bolts.
2 Carefully remove the driveshaft.





6. Mark the rear transfer case flange and the rear output shaft for proper assembly.





7. Remove the transfer case rear output flange.
1 Remove the nut.
2 Remove the washer.
3 Remove the seal.
4 Remove the rear transfer case rear output flange.





8. Use the Seal Remover and Impact Slide Hammer to remove the rear transfer case flange seal.


INSTALLATION





1. Use the Seal Replacer to install the rear transfer case flange seal.
2. Align the marks on the transfer case flange and the rear output shaft.





3. Position the rear transfer case rear output flange.
1 Position the rear output flange.
2 Position the seal.
3 Position the washer.
4 Position the nut.





4. Using the Companion Flange Holding Tool, tighten the rear output flange nut.





5. Align the marks on the driveshaft to driveshaft rear axle companion flange, and install the bolts.





6. Align the marks on the driveshaft yoke and transfer case companion flange, and install the driveshaft bolts.

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.

7. Lower the vehicle.