Intermediate Shaft Seal Deflector

Intermediate Shaft Seal Deflector













Removal

NOTE: This procedure is to be performed through the RH wheel opening. It is not necessary to remove the exhaust components to complete this repair.

1. Remove the intermediate shaft. For additional information, refer to Front Drive Halfshafts Front Drive Halfshafts.

2. NOTE: The following instruction will prevent the Transfer Case Bearing Cup Remover from opening too far which would make removing the intermediate shaft seal deflector difficult.

Place a 16 mm (5/8 in) washer between the components of the Transfer Case Bearing Cup Remover as shown.





NOTICE: Failure to utilize the recommended tools may result in serious damage to the Power Transfer Unit (PTU).

3. Assemble the special tools as indicated in the following table and illustration:









4. NOTE: Using a Slide Hammer Master Set eases the removal of the seal deflector.

Using the Bearing Cup Remover, the extension from the Halfshaft Remover and a suitable slide hammer, remove the seal deflector.

- The seal deflector will have been damaged during removal. Remove all foreign material from the PTU before continuing with the repair.





Installation

1. NOTICE: Do not overheat (melt) the seal deflector. Monitor the temperature of the deflector with a suitable temperature measuring device, such as a digital temperature laser or infrared thermometer, while heating. Do not allow the temperature to exceed 100°C (212°F). Overheating will damage the deflector. If the deflector is damaged, a new deflector must be used.

NOTE: Apply a small amount of silicone brake caliper grease and dielectric compound to the inner lip of the deflector where it installs on the tube inside the PTU before heating. This will ease the installation of the deflector.

Position the deflector on the PTU Linkshaft Seal Dust Shield Installer using silicone brake caliper grease and dielectric compound to retain it to the installer. Using a suitable heat gun, heat the deflector to a minimum of 71°C (160°F) and a maximum of 93°C (200°F) by concentrating the heat across the back of the installer while rotating the tool. Once the optimum temperature is achieved on the tool, move the heat gun to the front of the tool and heat the inside of the deflector where it snaps onto the PTU shaft until the temperature of the deflector is a minimum of 100°C (212°F).

- As an alternative method to heating the seal deflector, place the deflector in boiling water for 3 to 5 minutes. Dry off the deflector and install.





2. Using a 5-pound or larger dead blow hammer, install the seal deflector immediately after heating using the PTU Linkshaft Seal Dust Shield Installer and Driver Handle.





3. Make sure the deflector is completely seated all the way around and there are no cracks on the face. The deflector is correctly installed when the face of the deflector is recessed 3-5 mm (0.12-0.20 in) into the pocket all the way around.





4. Fully install the intermediate and halfshaft assembly and the 2 bolts.
- Tighten to 40 Nm (30 lb-ft).





5. NOTE: A significant amount of residual fluid will collect between the seal and deflector during this repair. This is a normal condition and should not be misinterpreted as a leak after the repair is complete.

Using metal brake parts cleaner, thoroughly clean the deflector and intermediate shaft area of any residual fluid that may have accumulated during the repair.

6. Fill the transaxle to the correct fluid level.