Seals and Gaskets: Service and Repair

Transfer Case Rear Output Shaft Seal









Removal and Installation

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

2. Index-mark the rear output flange and the driveshaft yoke.





3. NOTE: If new driveshaft yoke bolts are not available, coat the threads of the original bolts with threadlock and sealer.

Remove the 4 driveshaft yoke bolts.

- To install, tighten to 112 Nm (83 lb-ft) evenly in a cross pattern.





4. NOTICE: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable tool, to disconnect the driveshaft flange from the pinion flange or damage to the components can occur.

Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle pinion flange.





5. Position the driveshaft aside and support with mechanic's wire.





6. Using the Drive Pinion Flange Holding Fixture to hold the output flange, remove the nut.
- To install, tighten to 355 Nm (262 lb-ft).





7. Remove the output shaft yoke washer.

8. Using the Output Shaft Flange Remover, remove the rear output shaft flange.





9. Remove and discard the rear output shaft flange oil seal.

10. Using the Bushing Remover with the Slide Hammer, remove the rear output shaft oil seal.





11. Using the Input Shaft Oil Seal Installer, install a new rear output shaft oil seal.





12. To install, reverse the removal procedure.
- Always install a new rear output shaft flange oil seal.