TRANSFER CASE

Rear Output Shaft Seal

REMOVAL & INSTALLATION

1. Raise and safely support the vehicle.
2. Matchmark the rear driveshaft to the transfer case yoke then disconnect the shaft from the yoke. Wire the driveshaft up and out of the way.
3. Drain the transfer case oil.
4. Using a thin-wall socket, remove the rear output shaft yoke retaining nut.

   NOTE: Some fluid may dribble out as the yoke is removed, and then again when the seal is removed. While an old rag should suffice for catching the fluid, a small catch can may be better, especially if the vehicle is not parked level.

5. Remove the output shaft yoke washer, rubber seal and the yoke from the output shaft. On MPV models, use companion flange puller tool 49-0839-425C, or equivalent.
6. Remove the rear output shaft seal by prying and pulling on the curved outer lip of the seal. On the 1998 B Series Pick-up, use seal removal tool 49-0223-630B. Take care to not damage the bearing, bearing cage or case.

   To install:

7. Ensure that the output housing bore is free of any dirt, burrs or nicks. Apply molybdenum grease to the seal lip.
8. Position the new seal to the output housing and using an appropriate driver, such as the Output Shaft Seal Installer tool 49-U027-003 and Driver Handle 49-F027-003 (B Series Pick-up/Navajo) or 49-G030-797 (MPV), press the seal into the housing until fully seated.
9. Install the rear out put shaft yoke, rubber seal and washer.
10. Install the output shaft yoke retaining nut and tighten to 184–203 ft. lbs. (250–275 Nm).
11. Connect the rear driveshaft to the transfer case.
12. Add transfer case oil to the correct level.
13. Lower the vehicle.
14. Drive the vehicle and check for leaks.

    Fig. 2: Drive the new seal into the case housing using the appropriate seal installation tool