Seals and Gaskets: Service and Repair

Transfer Case Rear Output Shaft Seal

Rear Output Shaft Seal - Exploded View (Part 1):

Rear Output Shaft Seal - Exploded View (Part 2):

Removal
1. With the vehicle in NEUTRAL, position it on a hoist.

2. NOTE: Index-mark the front flange on the rear driveshaft and the flange on the transfer case.

Disconnect the rear driveshaft from the transfer case and position the driveshaft aside.
1 Index-mark the front flange on the driveshaft and the flange on the transfer case.
2 Remove and discard the 4 rear driveshaft-to-flange bolts.
3 Disconnect the driveshaft from the transfer case and position the driveshaft aside.





3. NOTE: Index-mark the rear output shaft and the flange.

NOTE: The nut has a self-locking feature. Discard the nut and the washer after removing them.

Use the special tool to prevent the flange from turning. Remove and discard the flange nut and the washer.





4. Using a suitable puller and the special tool, remove the flange.





5. Remove the oil seal if it remains on the rear output shaft.





6. Using the special tool, remove the rear output shaft seal.





Installation
1. Clean the seal mounting surface.
2. Using the special tool, install the new rear output shaft seal.





3. NOTE: Align the index marks.

NOTE: Be sure the oil seal is not on the shaft before installing the flange.

Position the flange on the rear output shaft.





4. Install a new oil seal in the flange.
5. Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 lb-ft) to seat the flange on the shaft.





6. Use the special tool to prevent the flange from turning. Install a new washer and a new flange nut.
^ Tighten to 210 Nm (155 lb-ft).





7. NOTE: Align the index marks. Install the driveshaft with new bolts. If new bolts are not available, coat the threads of the original bolts with Threadlock(R).

Connect the driveshaft to the transfer case and install the 4 rear driveshaft-to-flange bolts.
^ Tighten to 112 Nm (83 lb-ft).





8. Check the transfer case fluid level. If necessary, fill the transfer case to the correct level with the specified fluid.