Seals and Gaskets: Service and Repair

Transfer Case Rear Output Shaft Seal





Special Tool(s)





Material

Removal and Installation
1. With the transmission in NEUTRAL, raise and support the vehicle.





2. Index mark the rear output flange and the driveshaft yoke.





3. CAUTION: CAUTION: If new driveshaft yoke bolts are not available, coat the threads of the original bolts with threadlock and sealer.

Remove the 4 driveshaft yoke bolts.
^ To install, tighten the bolts to 112 Nm (83 ft. lbs.) evenly in a cross pattern.





4. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange.

Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle pinion flange.





5. Position the driveshaft aside and support with mechanic's wire.





6. Index mark the rear output flange and the upper output shaft.





7. Using the special tool to hold the output flange, remove the nut.
^ To install, tighten to 355 Nm (262 ft. lbs.).
8. Remove the output shaft yoke washer.
9. Remove the rear output shaft flange.
10. Remove and discard the rear output shaft flange oil seal.





11. Using the special tools, remove the rear output shaft oil seal.
12. To install, reverse the removal procedure.
^ Always install a new rear output shaft flange oil seal.





13. Using the special tool, install a new rear output shaft oil seal.