Double Seal In Drive Pinion, Replacing

5 SPD. A/T 01L AWD

Double seal in drive pinion, replacing
Special tools and equipment





3403 Right sealing ring installer





3403/1 Thrust washer for 3403 thrust piece





Note: An inspection opening is provided on the left side of the intermediate flange to check for oil leaks at the double seal in the drive pinion and the double seal in the intermediate flange.

Removing





^ Remove transfer case.
^ Remove intermediate flange for front final drive.
^ Carefully pull off drive pinion from drive shaft.

CAUTION: Spur gears which have fallen onto the ground may not be reinstalled. In this case the transfer case must be replaced,





^ Drive double seal out using appropriate drift

Installing
Installation is the reverse of removal. Also carry out the following procedures:
^ Drive 3403/1 thrust washer onto 3403 thrust piece.
^ Drive double seal onto 3403 thrust piece.
^ Drive in double seal with 3403 thrust piece (with 3403/1 thrust washer) to thrust piece stop.

Note: The contact surface -A- of thrust piece must lie against 340311 thrust washer. This thrust washer must then lie against drive pinion -B-.





^ Cover splines on end of shaft (arrow) with insulating tape to prevent damage to seal when installing drive pinion. Take care to cover splines completely, without creasing or overlapping tape.

Note: Make sure that the discs -B- are inserted in the proper order before installing drive sprocket; Refer to Fig. 1.

^ Place drive pinion in centered position on final drive. (Installation position.

CAUTION: The seating lips of the seat (arrow) may be damaged If the drive pinion Is placed on without proper care.

Fig. 1:

A Output shaft
The three discs:
1. Thrust washer
2. Roller bearing
3. Thrust washer with cone (cone faces transmission)

Note: All three discs are pre-determined and may not be replaced with any other parts.