TRANSFER CASE FRONT OIL SEAL REPLACEMENT

PROCEDURE


  1. AIR SUSPENSION CONTROL PROHIBITED (w/ Air Suspension)

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  2. DRAIN TRANSFER OIL

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  3. REMOVE FRONT PROPELLER SHAFT ASSEMBLY

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  4. REMOVE NO. 2 TRANSFER CASE PLUG

    B006AYR

    1. Using a 17 mm straight hexagon wrench, remove the No. 2 transfer case plug and transfer case plug gasket.

  5. REMOVE OUTPUT SHAFT COMPANION FLANGE SUB-ASSEMBLY


    1. B006DGPC04
      *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.

      SST
      09213-54015   ( 91651-60855 )
      09330-00021

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

  6. REMOVE TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

    B006AODN01

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

      SST
      09308-00010

      Note

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

  7. INSTALL TRANSFER OUTPUT SHAFT COMPANION FLANGE OIL SEAL

    B0069LZN01

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

      SST
      09316-60012   ( 09316-00011, 09316-00021 )
      09502-24010
      Standard oil seal depth
      2.5 to 3.0 mm (0.0985 to 0.118 in.) from the top edge of the case

      Tech Tips

      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.

  8. 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. B006CQZC01
      *a Turn
      *b Hold

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

      SST
      09213-54015   ( 91651-60855 )
      09330-00021
      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Tech Tips

      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.

  9. INSTALL NO. 2 TRANSFER CASE PLUG


    1. Using a 17 mm straight hexagon wrench, install a new transfer case gasket and the No. 2 transfer case plug.

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

  10. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

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  11. ADD TRANSFER OIL

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  12. INSPECT TRANSFER OIL LEAK