Rear
REAR OUTPUT SHAFT SEALREMOVAL
1. Shift the transmission and transfer case into NEUTRAL.
2. Raise and support vehicle.
3. Mark a line across the pinion shaft and at each end of the propeller shaft for installation reference.
4. Remove the U-joint strap bolts at the pinion shaft yoke.
5. Pry open clamp holding the dust boot to propeller shaft yoke (Fig. 87).
6. Slide the slip yoke off of the transmission/transfer case output shaft and remove the propeller shaft.
7. Spread band clamp which holds output shaft boot to the output shaft slinger, or output shaft damper, with a suitable awl, or equivalent.
NOTE: Vehicles built with a 4.0L engine and a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.
8. Remove output shaft boot from slinger, or output shaft damper, and output shaft.
9. If the vehicle is not equipped with an output shaft damper, remove the output shaft rear slinger using Puller MD-998056-A (Fig. 88).
10. If the vehicle is equipped with an output shaft damper, use Screws 8421 and the puller yoke and forcing screw from a bolt-grip puller set, such as those used to remove steering wheels and harmonic balancers, to remove the transfer case output shaft damper.
11. Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer (Fig. 89).
INSTALLATION
1. Apply liberal quantity of petroleum jelly to new rear seal and to output shaft. Petroleum jelly is needed to protect seal lips during installation.
2. Slide seal onto Seal Protector 6992 (Fig. 90). Slide seal protector and seal onto output shaft.
3. Slide Installer C-4076-B onto seal protector with the recessed side of the tool toward the seal. Drive seal into rear bearing retainer with Installer C-4076-B and Handle MD-998323 (Fig. 91).
NOTE: Vehicles built with a 4.0L engine and a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.
4. Install a new output shaft rear slinger with Installer 8408, if the vehicle is not equipped with an output shaft damper.
5. If the vehicle is equipped with an output shaft damper, install the output shaft damper as follows:
a. Position the damper weight on the output shaft. Start the damper onto the output shaft chamfer, being careful to keep the weight square to the output shaft. (Fig. 92)
b. Position the driver portion of Installer 8422 (Fig. 93) onto the damper, making sure the legs of the damper are positioned through the slots of the damper.
c. Thread the puller screw of Installer 8422 into the output shaft by hand only. Make sure the screw is fully threaded into the output shaft.
d. Using a wrench to hold the pulling screw stationary (Fig. 94), turn the pulling screw nut until the driver legs contact the rear face of the transfer case rear retainer. When the legs contact the retainer, the damper is properly positioned on the output shaft.
6. Install boot on output shaft slinger, or output shaft damper, and crimp retaining clamp with tool C-4975-A (Fig. 95).
7. Slide the slip yoke on the transmission/transfer case output shaft. Align installation reference marks at the axle yoke and install the propeller shaft.
8. Tighten the U-joint strap/clamp bolts at the axle yoke to 19 Nm (14 ft. lbs.).
9. Crimp clamp with Clamp Tool C-4975A to hold dust boot to propeller shaft yoke.
10. Remove support and lower the vehicle.