Front Output Shaft Seal Replacement

Front Output Shaft Seal Replacement

Special Tools
* J 8614-01 Flange and Pulley Holding Tool
* J 37212 Front Output Shaft Seal Installer

Removal Procedure

1. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement Transfer Case Fluid Replacement
2. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement Front Propeller Shaft Replacement.





Note: In order to easily remove the nut, ensure the staked areas are completely bent out from the shaft.

3. Using a suitable punch, bend the stakes out on the yoke flange nut.




4. Using the J 8614-01 to support the flange, loosen the yoke flange nut.




5. Remove the following:

* The yoke flange nut
* The O-ring seal
* The front output yoke flange
Discard the nut and O-ring seal.





Caution: Refer to Transfer Case Seal Removal Caution Service Precautions.

6. Lightly tap a flat bladed screwdriver around the edge of the front output shaft seal.




7. Pry the front output shaft seal from the transfer case.

Installation Procedure




1. Using the J 37212 and a hammer, install the NEW front output shaft seal into the transfer case.




2. Install the yoke flange to the front output shaft.
3. Lightly lubricate the NEW yoke flange O-ring seal with transfer case fluid.
4. Install the yoke flange O-ring seal.
5. Install a NEW yoke flange nut.





Caution: Refer to Fastener Caution Fastener Caution.

6. Attach the J 8614-01 to the yoke flange. Tighten the yoke flange nut to 137 Nm (101 lb ft).




7. Using a suitable punch, stake the yoke flange nut in 2 places.
8. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement Front Propeller Shaft Replacement.
9. Fill the transfer case fluid. Refer to Transfer Case Fluid Replacement Transfer Case Fluid Replacement.