Seals and Gaskets: Service and Repair

Transfer Case Rear Output Shaft Seal









Rear Output Shaft Seal - Exploded View









Removal

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

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 Drive Pinion Flange Holding Fixture to prevent the flange from turning. Remove and discard the flange nut and the washer.





4. Using a suitable puller and the Drive Pinion Flange Holding Fixture, remove the flange.





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





6. Using the Oil Seal Remover, remove the rear output shaft seal.





Installation

1. Clean the seal mounting surface.

2. Using the Drive Pinion Oil Seal Installer, install a new rear output shaft seal.





3. NOTE: Align the index marks.

NOTE: Verify 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 Transmission Output Shaft Flange Installer, install the flange. Tighten the nut on the Transmission Output Shaft Flange Installer to 54 Nm (40 lb-ft) to seat the flange on the shaft.





6. Use the Drive Pinion Flange Holding Fixture 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.

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. For additional information, refer to Transfer Case Draining and Filling Procedures.