Intermediate Shaft Seal and Deflector

Intermediate Shaft Seal and Deflector

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Material:

Removal

NOTE: This procedure will not affect the fluid level of the power transfer unit (PTU). Automatic transmission fluid (ATF) will leak when the intermediate shaft seal is removed. Add ATF to the transmission if necessary.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the intermediate shaft.

3. NOTE: The seal deflector will be damaged during removal.

Using the special tools, remove the seal deflector.





4. NOTE: The removal of the intermediate shaft can unseat the seal. Check the seal before installing the special tools.

NOTE: Clean the area around the seal deflector and seal.

Using the special tools, remove the intermediate shaft seal.





5. NOTE: There is a bearing inside the PTU, directly behind the cover seal. The bearing is not serviced.

If necessary, carefully remove the cover seal.

Installation
1. If necessary, install a new cover seal. Using the special tools, seat the cover seal.





2. Using the special tools, install the intermediate shaft seal.





3. CAUTION: Do not overheat (melt) the seal deflector. Overheating will damage the deflector. If the deflector is damaged, a new one must be used.

Using a suitable heat gun, heat the new seal deflector. Concentrate the heat across the back of the deflector near the white colored tabs. Install the seal deflector immediately after heating. An audible snap should be heard.
^ If necessary, use special tools 205-882 and 205-153 to seat the seal deflector. Make sure the deflector is fully seated and there are no cracks on the face or inner diameter white colored tab.
^ As an alternative method to heat the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off deflector and install.
^ Make sure the deflector is completely seated all the way around. It is correctly installed when the face of the deflector is recessed into the pocket.





4. Install the intermediate shaft.