Replacing the front output shaft seal
1 - Transfer case; 2 - Crankcase cover; 3 - Drain plug; 4 - Filler plug; 5 - Bolts; 6 - Bolts; 7 - Speed sensor; 8 - Rear propeller shaft output flange; 9 - Sealing ring; 10 - Washer; 11 - Nut; 12 - Servomotor; 010 - Assembly stand; 020 - Support plate
Replacing the front output shaft seal
1 - Transfer case; 13 - Chain drive sprockets; 13a - Drive chain; 14 - Retaining ring; 15 - Ball bearing; 16 - Front output shaft; 17 - Seal; 18 - Planetary gear; 19 - Rear output shaft
Replacing the front output shaft seal
17 — Seal
030 — Mandrel
1. Illustrative material on replacing the front output shaft seal of the transfer case is presented in the illustrations, to which all references in the text refer.
2. Unscrew the plug (3) and drain the oil from the transfer case housing.
3. Remove the transfer case (1) (see Section Removal and installation the transfer case) and fix it to the mounting stand (010) using the support plate (020).
4. Remove the rear outlet flange (8) (see Section Replacing the rear propeller shaft output flange seal).
5. Unscrew the mounting bolts (6) and remove the servomotor (12) together with the speed sensor (7).
6. Pull outward to remove the speed sensor (7).
7. Unscrew the bolts (5) and remove the cover (2).
8. Pull outward to remove the sprockets (13) together with the drive chain (13a).
9. Remove the retaining ring (14) and remove the front axle drive output shaft (16).
Note: When removing the snap ring, hold the shaft still.
10. Using a suitable screwdriver, remove the front output shaft seal (17) from its seat and install a new one in its place using a suitable mandrel (030) - before tapping the seal, secure the planetary gear assembly (18) to prevent it from falling out.
11. Install the front output shaft (16) in place and secure it with the retaining ring (14), making sure that the latter is securely seated in the receiving groove.
12. Install the chain drive assembly (13 and 13a).
13. Bolt the cover (2), after cleaning the mating surfaces and applying a suitable sealant.
14. Install the servomotor (12) and speed sensor (7) in place, tighten the mounting bolts (6).
15. Install the rear propeller shaft flange (see Section Replacing the rear propeller shaft output flange seal).
16. Fill the transfer case with fresh oil up to the level of the lower edge of the filler/inspection hole.
17. Finally, start the engine and check the transfer case for signs of developing leaks.