Replacing the front output shaft seal
1 - Transfer box; 2 - Crankcase cover; 3 - Drain plug; 4 - Filler plug; 5 - Bolts; 6 - Bolts; 7 - Speed sensor; 8 - Output flange of the rear propeller shaft; 9 - O-ring; 10 - Washer; 11 - Nut; 12 - Servo; 010 - Mounting stand; 020 - Base plate
Replacing the front output shaft seal
1 - Transfer box; 13 - Chain drive sprockets; 13a - Drive chain; 14 - Retaining ring; 15 - Ball bearing; 16 - Front output shaft; 17 - Oil seal; 18 - Planetary gear; 19 - Rear output shaft
Replacing the front output shaft seal
17 - Oil seal
030 - Mandrel
1. Illustrative material for replacing the front output shaft seal of the transfer case is presented in the illustrations, which include all references in the text.
2. Remove the plug (3) and drain the oil from the transfer case.
3. Remove the transfer case (1) (see Section Removal and installation of the transfer case) and fix it on the mounting stand (010) with base plate (020).
4. Remove rear outlet flange (8) (see Section Replacing the output flange seal of the rear propeller shaft).
5. Turn out fixing bolts (6) and remove the servomotor (12) complete with speed sensor (7).
6. Pulling outward, remove the speed sensor (7).
7. Turn out bolts (5) and remove the cover (2).
8. Pulling outward, remove the sprockets (13) complete with drive chain (13a).
9. Remove retaining ring (14) and remove the front axle drive output shaft (16).
Note. Hold the shaft steady when removing the retaining ring.
10. Using a suitable screwdriver, remove the oil seal (17) front output shaft from its seat and fit a new one in its place using a suitable drift (030), - before tapping the stuffing box, fix the planetary gear assembly (18) in order to prevent it from falling out.
11. Reinstall the front output shaft (16) and secure it with a retaining ring (14), following the reliability of the fit of the latter in the receiving groove.
12. Install chain drive assembly (13 and 13a).
13. Screw on the lid (2), by first cleaning the mating surfaces and applying a suitable sealant.
14. Replace the servomotor (12) and speed sensor (7), tighten the fixing bolts (6).
15. Install the rear driveshaft flange (see Section Replacing the output flange seal of the rear propeller shaft).
16. Fill the transfer case with fresh oil to the level of the lower cut of the filler / control hole.
17. Finally, start the engine and check the transfer case for signs of leaks.