Rear Output Flange and Driveshaft Seal, Transfer Case Installed

Rear Output Flange and Driveshaft Seal, Transfer Case Installed

Special tools, testers and auxiliary items required

• Puller (T10055)

• Adapter (T10055/2)

• Assembly Tool (T10399)

• Thrust Piece (T10450)

• Sealing grease (G 052 128 A1)

• With approximately 4 mm diameter screw

• Approximately 600 mm pry lever (for example 652-24 Hazet)

Removing

Place a rag on top of the exhaust system bracket.






- Remove the center support bolts - 1 - and set the driveshaft on the exhaust system.






- If equipped, remove the balance weight from the transfer case (4 bolts).






- Mark the installed location where the driveshaft and the transfer case and the rear final drive connect - arrow -.






Danger of damaging the driveshaft

• The pry lever - 1 - must be positioned on the push-on contact - arrow B - the driveshaft from the transfer case.

• The pry lever - 1 - will get damaged if is touching the boot. Then it will necessary to remove the driveshaft.








- Remove the driveshaft from the transfer case. Attach the pry lever - 1 - to the end of the hub on the driveshaft - arrow B -.

• The pry lever - 1 - must be supported on the surface - A arrow - when being removed.

• A locking ring secure the driveshaft to the flange and can be pulled off with a forceful pull.

- Secure the driveshaft sideways on the underbody so that it is up and out of the way.

- Use a pry lever - B - to press the dust cap off - A -.






- Use a needle-bearing drift to punch a hole in the center of the shaft seal.

- Install the 4 mm diameter screw - arrow -.






• Do not damage the sealing surface on the output shaft.

• Do not screw the screw in too tight or you will damage the bearing that is behind it.

- Use the (T10055) to remove the shaft seal.






Installing

- Apply a light layer of lubricant on the outer circumference of the shaft seal.

- Fill the space between the sealing and dust lips halfway with sealing grease (G 052 128 A1).

- Install the new shaft seal all the way without tilting it.






- Press a new dust cap - A - on until it latches securely on the shaft.






- Replace the O-ring - A - and locking ring - B -.






- Install the driveshaft on the transfer case and center support. Refer to => [ Rear Driveshaft ] Rear Driveshaft.

- Check the transmission fluid level in the transfer case. Refer to => [ Gear Oil Level in the Transfer Case, Checking ] Gear Oil Level In the Transfer Case, Checking.