Transfer Case Rear Output Shaft Flange

TRANSFER CASE REAR OUTPUT SHAFT FLANGE





Special Tool(s)





Materials

Removal
1. With the vehicle in NEUTRAL, raise and support the vehicle.





2. CAUTION: Index-mark the front flange on the rear driveshaft and the flange on the transfer case.

Disconnect the rear driveshaft from the transfer case and position the driveshaft aside.
1. Index-mark the front flange on the driveshaft and the flange on the transfer case.
2. Remove and discard the four bolts.
3. Disconnect the driveshaft from the transfer case and position the driveshaft aside.





3. CAUTION: Index-mark the rear output shaft and the flange.

CAUTION: The nut has a self-locking feature. Discard the nut and the washer after removing them.

Using the special tool to prevent the flange from turning, remove and discard the nut and the washer.





4. Using a suitable puller, remove the flange.





5. Remove the oil seal if it remains on the rear output shaft.

Installation
1. Install the oil seal in the flange.





2. CAUTION: Align the index marks.

Position the flange on the rear output shaft. If necessary, reseat the oil seal in the flange.





3. Using the special tool, install the flange. Tighten the nut on the special tool to 54 Nm (40 ft. lbs.) to seat the flange on the shaft.





4. Using the special tool to prevent the flange from turning, install the new washer and the new nut.





5. CAUTION: Align the index marks.

NOTE: Install the driveshaft with new bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.

Connect the driveshaft to the transfer case and install the bolts.
6. Lower the vehicle.