Transfer Case Rear Output Shaft Seal

Transfer Case Rear Output Shaft Seal





Special Service Tools

Removal

1. NOTE: This process only applies to vehicles up to and including VIN305488.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.





2. Remove the fuel tank heat shield.
^ Remove the 3 bolts and 2 nuts.

3. CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.

CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

Release the driveshaft from the transfer case drive flange.
^ Remove the 6 Torx bolts and washers.





4. CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

Lower the front end of the driveshaft.
^ Remove the 2 driveshaft center bearing mount bolts.
^ Support the driveshaft.





5. Using the special tools, remove the drive flange.
^ Remove and discard the snap ring.





6. CAUTION: Care must be taken to avoid damage to the seal register and running surface.

Remove the transfer case rear output shaft seal.

Installation





1. CAUTION: Oil seals must be fitted dry.

Using the special tool, install a new oil seal.
^ Clean the component mating faces.

2. CAUTION: Extreme care must be taken when starting the snap ring and engaging the splines.

Install the drive flange. Clean the component mating faces. Install a new snap ring. Lubricate the bearings. Make sure the snap ring is fully engaged and retains the drive flange.
3. Attach the driveshaft to the transfer case drive flange.
^ Tighten the Torx bolts to 55 Nm (40 ft. lbs.).
^ Clean the component mating faces.

4. CAUTION: Align the driveshaft center bearing mount by moving the floating front section of the shaft backward or forwards until the bolt holes in the mount align with the holes in the chassis.

Install the driveshaft center bearing mount bolts.
^ Align the bearing by moving the front section of the driveshaft.
^ Tighten the driveshaft center bearing retaining bolts to 30 Nm (22 ft. lbs.).
5. Install the fuel tank heat shield. h Tighten the bolts and nuts to 10 Nm (7 ft. lbs.).
6. Check and top-up the transfer case fluid level.