TRANSFER CASE REAR OIL SEAL REPLACEMENT

PROCEDURE

1. Click here

   AIR SUSPENSION CONTROL PROHIBITED (w/ Air Suspension)

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2. Click here

   DRAIN TRANSFER OIL

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3. Click here

   REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

   Click here

4. Click here

   REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

   
   
   1. 

      Using SST and a hammer, loosen the staked part of the transfer output shaft nut.

      09930-00010

      Note:
      

      • Completely loosen the staked part of the transfer output shaft nut.

      • Be careful not damage the threads of the No. 1 differential case.

      • Use SST with the tapered surface facing the No. 1 differential case.

      • Do not grind the end of SST with a grinder or other tool.

   2. 

      *a	Turn
      *b	Hold

      Using SST, hold the drive pinion companion flange sub-assembly in place.

      09330-00021
      09950-30012	09955-03040

      Tip:

      Use M10 x P1.25 bolts and nuts with a length beneath the head of 35 mm to secure SST to the drive pinion companion flange.

   3. Using a 30 mm socket wrench, remove the transfer output shaft nut.

   4. 

      *a	Turn
      *b	Hold

      Using SST, remove the drive pinion companion flange sub-assembly and 2 transfer output shaft washers.

      09950-30012

      09951-03010

      09953-03010

      09954-03010

      09955-03040

5. Click here

   REMOVE TRANSFER EXTENSION HOUSING OIL SEAL

   
   
   1. 

      Using SST, remove the transfer extension housing oil seal.

      09308-00010

      Note:

      Be careful not to damage the surface of the transfer extension housing that contacts the transfer extension housing oil seal.

6. Click here

   INSTALL TRANSFER EXTENSION HOUSING OIL SEAL

   
   
   1. 

      Using SST and a hammer, tap in a new transfer extension housing oil seal to the position shown in the illustration.

      09316-60011

      09316-00011

      Standard oil seal depth
      12.0 to 12.5 mm (0.4725 to 0.492 in.) from the top edge of the case

   2. Apply a small amount of MP grease to the lip of the transfer extension housing oil seal.

7. Click here

   INSTALL DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY

   
   

   1. Temporarily install the 2 transfer output shaft washers and drive pinion companion flange sub-assembly to the transfer assembly with a new transfer output shaft nut.

   2. 

      *a	Turn
      *b	Hold

      Using SST, hold the drive pinion companion flange sub-assembly in place.

      09330-00021
      09950-30012	09955-03040

      Tip:

      Use M10 x P1.25 bolts and nuts with a length beneath the head of 35 mm to secure SST to the drive pinion companion flange.

   3. Using a 30 mm socket wrench, tighten the transfer output shaft nut.

      142 N*m

      1448 kgf*cm

      105 ft.*lbf

   4. Using a chisel and hammer, stake the transfer output shaft nut.

8. Click here

   INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

   Click here

9. Click here

   ADD TRANSFER OIL

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10. Click here

    INSPECT TRANSFER OIL LEAK