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TRANSFER CASE FRONT OIL SEAL REPLACEMENT

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PROCEDURE


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    AIR SUSPENSION CONTROL PROHIBITED (w/ Air Suspension)

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    DRAIN TRANSFER OIL

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    REMOVE FRONT PROPELLER SHAFT ASSEMBLY

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    REMOVE TRANSFER CASE PLUG


    1. Using a 17 mm straight hexagon wrench, remove the transfer case plug and N0. 2 transfer case plug gasket.

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    REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. B004SYRC02
      *a Turn
      *b Hold

      Using SST, hold the output shaft companion flange sub-assembly in place and remove the transfer output shaft companion flange bolt.

      09213-54015 91651-60855
      09330-00021

    2. Remove the output shaft companion flange sub-assembly from the transfer assembly.

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    REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. Using SST, tap out the transfer output shaft companion flange oil seal.

      09308-00010
      Note:

      Be careful not to damage the transfer output shaft companion flange oil seal or front transfer case contact surface.

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    INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL


    1. Using SST and a hammer, tap in a new transfer output shaft companion flange oil seal to the position shown in the illustration.

      09316-60011 09316-00011 09316-00021
      09502-24010
      Standard oil seal depth
      2.5 to 3.0 mm (0.0985 to 0.1181 in.) from the top edge of the case
      Tip:

      Assemble SST and wrap SST with vinyl tape to hold it together.

    2. Apply a small amount of MP grease to the lip of the transfer output shaft companion flange oil seal.

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    INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. Temporarily install the output shaft companion flange to the transfer assembly with the transfer output shaft companion flange bolt.

    2. B004VL4C02
      *a Turn
      *b Hold

      Using SST, hold the transfer output shaft companion flange in place and tighten the transfer output shaft companion flange bolt.

      09213-54015 91651-60855
      09330-00021
      85 N*m 867 kgf*cm 63 ft.*lbf
      Tip:

      Use M8 x P1.25 bolts with a length beneath the head of 55 mm to secure SST to the output shaft companion flange sub-assembly.

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    INSTALL TRANSFER CASE PLUG


    1. Using a 17 mm straight hexagon wrench, install a new transfer case gasket and the transfer case plug.

      98.1 N*m 1000 kgf*cm 72 ft.*lbf
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    INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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    ADD TRANSFER OIL

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    INSPECT TRANSFER OIL LEAK