How to Change an Output Shaft Seal
Changing the output shaft seal is a project that a do-it-yourself mechanic can do at home, with the right hand tools. Here are some of the steps involved.
Step 1: Jack Car Up
Jack the car up and place it on jack stands. All 4 wheels should be set on jack stands, as the car needs to be level in order to change the output shaft seal.
Step 2: Drain Transfer Case Fluid
Once the car is lifted in the air, drain out the transfer case fluid. Place a bucket under the drain plug, and use a square bit to remove the drain plug.
Step 3: Remove Drive Shaft
Use the socket set, and loosen the bolts on the drive shaft. Remove it from the output shaft of the transfer case.
Step 4: Remove Output Flange
After the driveshaft has been removed, you will see the output flange. Remove the 1 nut that holds it in place, and remove it from the transfer case.
Step 5: Remove and Change Output Shaft Seal
The output shaft seal is located in the housing around the output shaft. Remove this with a pry bar or a seal puller. Make sure not to scratch the shaft. Install the new seal and replace the flange and drive shaft. Fill with new transfer case fluid and lower the vehicle.