Transfer Case Inner Halfshaft Seal

Transfer Case Inner Halfshaft Seal





Special Tool(s)

Removal
1. Drain the transfer case.
2. Remove the transfer case.





3. Remove the transfer case vent tube.
^ Remove the two bolts.





4. Remove and discard the dust shield.





5. CAUTION: The transfer case cover is located to the case using two hollow dowels. Remove the cover squarely from the dowels to avoid cracking the cover bosses.

Remove the bolts and the transfer case cover.





6. Remove the three gears.





7. Remove the inner seal.

8. CAUTION: Transfer case cover and case sealing surfaces must be free of grease prior to applying new silicone sealant.

Clean the transfer case sealing surfaces.

Installation





1. Using the special tool, install the inner seal.





2. CAUTION: Take care not to roll the transfer case inner halfshaft seal lip when installing the drive gear.

Install the three gears.
1 Install the drive gear.
^ Install the drive gear using a slight rotation to prevent damaging the transfer case inner halfshaft seal.
2 Install the idler gear.
3 Install the driven gear.





3. CAUTION: The transfer case cover must be installed within 15 minutes of applying the silicone sealant. If the time limit is exceeded, clean the sealing surfaces and reapply.

NOTE: Apply a 1/8-inch bead of silicone gasket and sealant to the sealing surface of the transfer case cover before installing on the transfer case.

Install the transfer case cover.
^ Install the bolts in a cross pattern.





4. Install a new dust shield.





5. Install the transfer case vent tube.
^ Install the bolts.
6. Install the transfer case.
7. Fill the transfer case.
8. Check the transaxle fluid level.