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How-to » Transmissions & Drivetrains » 4WD & All Wheel Drive » How to Replace a Transfer Case Front Output Seal
 Note: This is a general guide for all vehicles.

How to Replace a Transfer Case Front Output Seal

PARTS
  • Sealant
  • Transfer Case Seal
TOOLS
STEPS
Edit
Hard
This guide requires the following supplies:
  • Thread locking compound
  • White out

Safety Tip:
Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or closed toe shoes.

1
Secure your vehicle on a level surface, making sure your vehicle will not roll or lean when jacked up.
2
Using a floor jack, lift up the front of your vehicle.
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3
Secure the vehicle with jack stands on both sides for safety before starting any work. The pinch welds or the frame rails are the two best locations. Do not rely on the jack alone to hold the vehicle up while working.
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4
Locate the transfer case front output seal.
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5
Use white out to put a mark/line on the driveshaft as well as on the yoke to insure correct realignment. Disconnect the driveshaft at the yoke and lower the driveshaft from the transfer case.
6
Remove the nut and washer from the yoke and pull the yoke from the transfer case.
7
Using a punch and hammer, carefully tap on the face of the seal to help pivot the seal out of the transfer case.
8
Spray brake cleaner on a rag and clean the transfer case bore.
9
Coat the inside of the new seal with ATF and the outside of seal with sealant.
10
Using a seal driver and hammer, position the seal squarely into the bore and drive it into place.
11
Install the yoke assembly. Apply thread lock to the output shaft and torque the nut to the manufacturer's specifications.
12
Install the driveshaft back onto the yoke assembly. Torque the u-joint mounting bolts to the manufacturer's specifications.
13
Lower vehicle from the jack stands and road test to ensure repair.
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