TRANSFER CASE REAR OIL SEAL REPLACEMENT

PROCEDURE


  1. DRAIN TRANSFER OIL

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  2. REMOVE PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  3. REMOVE DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


    1. A000U8BE01

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

      SST
      09930-00010

      Note


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

      • Do 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. A000U0ME01

      Using SST, hold the companion flange in place.

      SST
      09330-00021
      09950-30012   ( 09955-03040 )

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

    4. A000UCPE07

      Using SST, remove the companion flange and 2 transfer output shaft washers.

      SST
      09950-30012   ( 09951-03010, 09953-03010, 09954-03010, 09955-03040 )

  4. REMOVE TRANSFER EXTENSION HOUSING OIL SEAL


    1. A000TAHE01

      Using SST, remove the oil seal.

      SST
      09308-00010

      Note

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

  5. INSTALL TRANSFER EXTENSION HOUSING OIL SEAL


    1. A001052E01

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

      SST
      09316-60011   ( 09316-00011 )
      Standard oil seal depth
      12.0 to 12.5 mm (0.4724 to 0.4921 in.) from the top edge of the case

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

  6. INSTALL DRIVE PINION COMPANION FLANGE SUB-ASSEMBLY


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

    2. A000TAXE01

      Using SST, hold the companion flange in place.

      SST
      09330-00021
      09950-30012   ( 09955-03040 )

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

      Torque:
      142 N*m  { 1448 kgf*cm, 105 ft.*lbf }

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

  7. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

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  8. ADD TRANSFER OIL

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