My transfer case is leaking at the front output shaft. So, looking through a bunch of old threads I matched my problem to the pics that urn.frosh posted a while back. It turns out that his problem was the output shaft seal.

Anybody know *how* to replace that seal? I only have a good set of basic tools (sockets, wreches, etc..). I've gone over the instructions in a cheapy online manual, and it didn't make any sense to me. "Remove _____" is pretty vague.

If anybody has an idea, I'd greatly appreciate it.






Oh...there's a crap-ton of 2nd gen xfer case problems in the 3rd gen/taco forums...

 

Involves dropping the transmission. You up to that? Depending on your mileage, good time to do clutch service as well (if 5spd).

I browsed around on Pirate looking for a how-to, but didn't get anything specific. Didn't spend a lot of time though.

 

What?! Drop the transmission to replace the output seal? Ouch.
We are talking about the seal at the front driveshaft, yes?

Edit: Even the FSM is vague.
http://www.deserted1.com/FSM/Repair_...ilsea/repl.pdf

Edit: You're in Michigan..where abouts?

 

my rear output seal was leaking awhile back.. About two months after i had my clutch replaced. I had the same shop that did my clutch replace the seal..

it cost me about $300

 

No need to drop the tranny to replace the front tcase seal. My FSM is also vague, but it basically says to unstake the nut, remove it, pull out the flange and seal and replace seal and flange. The torque for the nut is 91 ft lb, and it should be restaked. That's for a 2nd gen but I would expect the 3rd to be very similar.

 

That sounds like 3 hours of labor or so. In fact, thats less than what a lot of people pay to have their axle seals replaced..which should be a relatively easy task. Unless the M/T case is differen't (I'm 90% certain it isn't), dropping the tranny doesn't sound necessary.

Somebody must have done this.

 

Front output seal. Meaning front driveshaft?

Remove the driveshaft,companion flange, seal/bearing retainer, knock out the seal, drive in a new one, scrape old gasket material from both T-case housing, and seal/bearing retainer, install new gasket, seal retainer, companion flange, driveshaft, done.

edit:
Don't forget top top off the T-case fluid when done.
The companion flange may need a "speedi sleeve" if it is grooved/worn by the old seal riding on it.

 

I stand corrected. Someone on Pirate was referring to a trans drop when changing the seal.

I'm about 2hrs away from you, Linden, south of Flint.

 

I guess I just need to get in there and do it because I have no idea what a companion flange, or speedi sleeve is.

I'll let you guys know how it went..maybe take a few pics.

 

The companion flange is what the driveshaft bolts up to.

A speedy sleeve is used when a groove is worn into the companion flange "nose" [ internal cannot be seen until it's apart ] that rides on the seal.