Engine/Transmission (1998.5 - 2002) Transfer case leak.

[MFranz]

I have a leak at the rear seal of my transfer case. Its a black

oily substance. I had just recently changed the transfer case oil. I beleive that I overfilled it. The questions are If the fluid is clean inside the transfer case why is it dark and oily at the seal. If im going to replace the rear seal do I need to replace the extension housing bushing and if so do I need special tools and where would I get them.

Thanks In Advance

Mike

 

[SRadke]

No special tools required to replace the rear t-case seal. Just remove the driveline, pry it out, and tap in a new one.



-Scott

 

[MFranz]

Transfer Case leak

Thanks Scott for the Info. Is it hard to get the Driveline

off. How long does it take.

Thanks In Advance

Mike

 

[SRadke]

Assuming you have a second gen because of the forum.....



No, it's not hard. There will be a pair of small u-bolts holding the u-joint to the yolk on the rear diff. Remove those and the back end is free. (note: Do not let the caps fall off the u-joint. A couple wraps of electrical tape works well to hold 'em. Otherwise you're picking up needle bearings) If you have a stretch cab long box you'll have a carrier bearing you need to take loose as well. The transfer case end is on a spline and it will slide right out. It may have one odd tooth, I'm not sure but if it does you'll have to get it back in in the same place. I don't think this will be the case. If it is it only goes one way, you can't go wrong.



The seal has a metal lip around it. You can try to pry it out but this is usually futile. I generally have to bend the lip out wiht a hammer and punch then grab it with a pair of vice grips and pull it out. Sometimes a tap on the vice grips with the hammer to make it slide. They can be stubborn. Don't worry about ruining it upon removal, that always happens but be sure they've sold you the right one to replace it before you do. There are two sizes that are obviously diffrent so if it looks right it likely is. Your new seal may or may not have a dust boot. The new on should tap right in, nice and square.



If I were doing the job, an hour tops. For a mechanical first timer, may be two. It really is pretty basic. Good luck.



-Scott

 

[MFranz]

Thanks Scott,. Im off to get a new seal.

Take Care

Mike