Intermediate Shaft Seal and Deflector

Intermediate Shaft Seal and Deflector

Intermediate Shaft Seal and Deflector:

Removal

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

1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the intermediate shaft.

3. CAUTION: 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.

Using the special tools, remove the intermediate shaft seal.
^ Clean the area around the seal deflector and 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. Use a suitable socket to install the intermediate shaft seal. The socket should be 39.5 mm (1.55 inch) to 40.5 mm (1.59 inch) in diameter. Using tape, index-mark the socket at 18 mm (0.7 inch).





3. Make sure the seal is centered in the bore, install a new intermediate shaft seal.





4. 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 308-430 and 308-431 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 alternate 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.





5. Install the intermediate shaft.