TRANSFER CASE FRONT OIL SEAL REPLACEMENT

PROCEDURE


  1. DRAIN TRANSFER OIL

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  2. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

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  3. REMOVE TRANSFER CASE PLUG

    A0019QD

    1. Using a 17 mm straight hexagon wrench, remove the plug and gasket.

  4. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

    A001BP6E01

    1. Using SST, hold the companion flange in place and remove the companion flange bolt.

      SST
      09213-58013
      09330-00021

    2. Remove the companion flange from the transfer assembly.

  5. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

    A001F3EE03

    1. Using SST, tap out the oil seal.

      SST
      09308-00010

      Note

      Be careful not to damage the oil seal or front transfer case contact surface.

  6. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

    A001F18E01

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

      SST
      09316-60011   ( 09316-00011, 09316-00021 )
      09502-24010

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

      SST
      09316-60011   ( 09316-00011, 09316-00021 )
      09502-24010
      Standard oil seal depth
      2.5 to 3.0 mm (0.0984 to 0.1181 in.)

    3. Apply a small amount of MP grease to the lip of the oil seal.

  7. INSTALL OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY

    A001EEYE03

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

    2. Using SST, hold the companion flange in place and tighten the companion flange bolt.

      SST
      09213-58013
      09330-00021
      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

  8. INSTALL TRANSFER CASE PLUG

    A0019QD

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

      Torque:
      98 N*m  { 1000 kgf*cm, 72 ft.*lbf }

  9. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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  10. ADD TRANSFER OIL

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