REMOVAL & INSTALLATION
| WARNING | Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system. When servicing vehicle, use care to avoid accidental air bag deployment. SIR system-related components are located in various locations throughout interior and exterior of vehicle, depending on application. Do not use electrical test equipment on or near these circuits. If necessary, deactivate SIR system before servicing components. See appropriate AIR BAG DEACTIVATION PROCEDURES in GENERAL INFORMATION. |
| CAUTION | When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle. See COMPUTER RELEARN PROCEDURES article in GENERAL INFORMATION before disconnecting battery. |
| CAUTION | Use correct fastener in correct location. Replacement fasteners must be correct part number for that application. Fasteners requiring replacement or fasteners requiring use of thread locking compound or sealant are identified in service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. |
Removal
- Raise and suitably support the vehicle.
- Remove the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155026-S06830641402003061000000).
- Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES. CAUTION: The front output shaft seal is a two piece internal seal. The inner seal race is a force fit on the front output shaft.
- Insert a flat-tipped screwdriver into the inner race. (Scheme 1)
- Pry the inner race back.
- Insert a small pry bar into the inner race. NOTE: When performing the following service procedure, the outer part of the seal will slightly move out of the transfer case with the inner part seal.
- Pry the inner part of the seal from the outer seal body.
- Remove the inner part of the seal. (Scheme 2)
- Insert a flat-tipped screwdriver or a small pry bar in the space between the outer race of the seal and the transfer case.
- Pry the outer race out of the transfer case.
- Remove the outer part of the seal. (Scheme 3)
Scheme 1
Scheme 2
Scheme 3
Installation
- Install the output shaft seal installer to the driver handle.
- Install a NEW seal onto output shaft seal installer.
- Using output shaft seal installer and driver handle, install the seal. (Scheme 4)
- Install the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
- Check the fluid level. See «CHECKING FLUID LEVELS»(ref-155026-S31671065832003061000000). Add fluid, if necessary.
- Install the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155026-S06830641402003061000000).
- Lower the vehicle.
Scheme 4
- Raise and suitably support the vehicle.
- Remove the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155026-S06830641402003061000000).
- Remove the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
- Remove the rear output shaft seal by prying it out with a flat tipped screwdriver. (Scheme 5)
- Inspect the rear output shaft bushing for scoring or wear.
- Remove the rear output shaft bushing if required, using the transfer case rear bushing remover/installer as follows: Install the finger section of the transfer case rear bushing remover/installer into the front of the bushing. (Scheme 6) Install the tube and forcing screw to the finger section. Ensure the forcing screw is backed out. Using a wrench on the forcing screw, remove the rear output shaft bushing.
Scheme 5
Scheme 6
- Using the transfer case rear bushing remover/installer, install a NEW rear output shaft bushing as follows: Install the bushing or the finger section of the transfer case rear bushing remover/installer. (Scheme 7) Install the finger section to the main body of the transfer case rear bushing remover/installer. Position the bushing and tool to the case. Using a hammer and the transfer case rear bushing remover/installer, install the bushing.
- Using output shaft seal installer, install a NEW front output shaft seal. (Scheme 8)
- Install the rear drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLES.
- Check the fluid level. Add fluid, if necessary. See «LUBRICATION»(ref-155026-S07148752572003061000000).
- Install the transfer case shield, if equipped. See «TRANSFER CASE SHIELD»(ref-155026-S06830641402003061000000).
- Lower the vehicle.
Scheme 7
Scheme 8
- Raise and suitably support the vehicle.
- If equipped with NVG 149, NVG 261 or NVG 263, disconnect speed sensor electrical connector (4). (Scheme 9)
- If equipped with NVG 246, disconnect speed sensor electrical connectors (3, 4 or 5). (Scheme 10)
- On all models, remove the speed sensor and "O" ring, discard the "O" ring. (Scheme 11)
Scheme 9
Scheme 10
Scheme 11
- Install the speed sensor with a NEW "O" ring. (Scheme 11) Tighten speed sensor to specification. See «TORQUE SPECIFICATIONS»(ref-155026-S01643392932003061000000).
- If equipped with NVG 246, connect speed sensor electrical connectors (3, 4 or 5). (Scheme 10)
- If equipped with NVG 149, NVG 261 or NVG 263, connect speed sensor electrical connector (4). (Scheme 9)
- On all models, lower vehicle.
- Raise and suitably support the vehicle.
- Remove the transfer case shield bolts/screws and remove the transfer case shield. (Scheme 12)
Scheme 12
- Position the transfer case shield and install the transfer case shield bolts/screws. (Scheme 12) Tighten bolts/screws to specification. See «TORQUE SPECIFICATIONS»(ref-155026-S01643392932003061000000).
- Lower the vehicle.