Transfer Case

Rear Output Shaft Oil Seal

Removal & Installation

To Remove:

1. Put the vehicle in NEUTRAL then raise and safely support the vehicle.

   CAUTION
   Make alignment marks on the front flange on the rear driveshaft and the flange of the transfer case.

2. Disconnect the rear driveshaft from the transfer case.

   NOTE: Make alignment marks on the rear output shaft and the flange.

   CAUTION
   Discard the nut and washer after removal. The nut has a self-locking feature.

3. Use the drive pinion flange holding fixture (205-126) to keep the flange from turning. Discard the nut and washer after removal.
4. Use an appropriate puller to remove the flange.
5. If the oil seal remains on the rear output shaft, remove the oil seal.
6. Use the oil seal remover (303-409) to remove the oil seal.

To Install:

1. Make sure the seal mounting surface is clean.
2. Use the drive pinion oil seal installer (205-304) to install the new oil seal.

   CAUTION
   Line up the alignment marks made during removal.

   NOTE: Make sure the oil seal is not on the shaft before installing flange.

3. Place the flange on the rear output shaft. Reseat the oil seal in the flange, if needed.
4. Install a new oil seal in the flange.
5. Use the transmission output shaft flange installer (205-495) to install the flange. To seat the flange on the shaft correctly,
   • Torque the nut on the transmission output shaft flange installer (205-495) to 40 ft-lb (54 Nm).
6. Use the drive pinion flange holding fixture (205-126) to keep the flange from turning. Install a new washer and nut.
   • Torque to 162 ft-lb (210 Nm).

   NOTE: Line up the alignment marks made during removal.

   NOTE: Install new bolts in the driveshaft. Coat the threads of the original bolts with threadlock and sealer if new bolts are not available.

7. Connect the driveshaft to the transfer case and install bolts.
   • Torque to 82 ft-lb (111 Nm).
8. Check the fluid level of the transfer case. Fill the transfer case to the correct level if needed.
9. Lower the vehicle.