Engine/Transmission (1998.5 - 2002) Transfer Case Rear Seal

[CEHughes]

Below are the instructions from replacement of rear seal on transfer case - anyway to get away without the specialty tools??? I will find a way to get them if I need to, but I am about 70 miles from the city, so I wanted to get everything I need today, so I won't have to drive in tomorrow.



Thanks for any help. Charles



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Rear Retainer Bushing and Seal



REMOVAL





Raise and support vehicle.

Remove rear propeller shaft.

Using a suitable pry tool or slide-hammer mounted screw, remove the rear retainer seal.

Using Remover 8158, remove bushing from rear retainer.



INSTALLATION



Clean fluid residue from sealing surface and inspect for defects.

Position replacement bushing in rear retainer with fluid port in bushing aligned with slot in housing.

Using Installer 8157, drive bushing into housing until installer seats against case.



Using Installer D-163, install seal in rear retainer (Fig. 16).

Install propeller shaft.

Verify proper fluid level.

Lower vehicle.

 

[BGarofalo]

I dont know if i have the same transfer case (NV 241) but on my 95 i just did a complete rebuild of the whole transfer case. If you are just doing the rear output seal just drop the drive shaff and drain the fluid out of the case. Then pull the four bolts on the tailhousing and it comes right off. Put it in a vise and use a socket and extension to hammer out the seal and tap in a new one. Glob some rtv silicone on the housing and bolt it back up. Refill case and put shaft back on. Thats just my opinion. It dosent have to be done that way but it is easier to get the seal straight on a bench standing up than laying on your back.

 

[CEHughes]

Thanks for the info - I did forget to mention that it is on the floor right now next to my transmission - getting new clutch - which is why it makes sense to repalce now and there is a layer of fluid on underbody that certainly appears to be coming from that seal - Thanks

 

[CEHughes]

I know this is not an exciting thread

... but I could really use some advise - I do not want to re-install this transfer case until I can reseal the ext housing properly. I tried to split it would not - seperate. Clarification - the seal broke, but it will not seperate and I did not want to force it. It spins partially, but is hanging up something.



Any advise would be appreciated.

 

[Mr. C]

Under the black rubber plug at the top of the tail housing is a external snapring that holds the tail housing to the rear bearing, expand the snap ring and the tail housing should slide off. This is a major pain to do while in the truck, trust me you are lucky it's on the ground. This is with the assumption you have the 241HD X-fer case.

 

[CEHughes]

Thanks - I did find it after some additional searching under better light.