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Transfer Case Seal Replacement
Contributed By: Jay Rexroad
There are three places I'd consider most likely to be leaking. The rear output shaft seal, the front output shaft seal, or the input shaft seal. Other possibilities are the seals at the hi/lo shift linkage or the 4WD vacuum solenoid thingy. Also, maybe the least likely, the gaskets between the various components of the housing.
If it's the input shaft seal, the t-case does have to be removed from the transmission to get to it.
Whether it's the front or rear, the procedure is basically the same.
So, there it is. Can you replace the output shaft seals without dropping the t-case? Yeah, and it SHOULD be a relatively easy job.
Is it that much easier than just biting the bullet and dropping the case in the first place? Well, it depends on how stubborn your old seals are, and you won't know that till you try. Besides, dropping the case will give you more room for working, but that's no guarantee you'll be able to remove the seals easily and without damaging the bores. Of course, with the t-case removed, you could disassemble it and drive the seals out from the other side, but that would be my absolute last resort.
When I ran into trouble with this, (Incidentally, this was before I got my computer and joined the list. I was on my own... not good) I considered dropping the t-case to alleviate my pain, But, my ego said that would be tantamount to failure. I mean, how could a simple seal job force me to do something I didn't want to, like drop the t-case? I was determined to show it who was boss... yadda, yadda, yadda.
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