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Transfer case Leak

1.9K views 8 replies 5 participants last post by  **DONOTDELETE**  
G
#1 ·
1988 Samurai

I am getting a leak behind the transfer case where the drive axle connects to the rear dif. I am assuming that it is a seal issue. First off is this a safe assumpion? Second is the process of taking it out straight forward. Will any special tools be requried?

Thanks

 
#2 ·
monteie

1. remove driveshaft
2. Remove nut the holds flange{open the portion of the nut that has been pounded in towards shaft}
3. Pull flange off shaft
4. Remove bad seal

Reverse procedure to install and re-torque nut to spec.

Thx
DannyL
Pony Express

88.5 5.5" SPOA,8K Warn,4.16's,TuffySkid Plate, Custom bumpers,nerfs.
http://www.partszuki.homestead.com/cover.html
 
#4 ·
Ah but the special tools im yearnin for are a thickly insulated garage with a thermal heated concrete floor, 4x4 post holes in the concrete for straitening frames and pulling whatnot, a paint room with filter intake and breathing line, a full 10,000 pound lift, engine hoist, parts scrubber tub, a big salamander heater, and my list is too big on tools but santa knows. Oh yes, a cot to sleep on when i have to power nap on ideas.

Just one more of the elite Samurai!/wwwthreads_images/icons/wink.gif External cage on a hardtop, x8ki wrn winch, M/L's,pny crb,98amp alt,32's, lckd f/r, j**p eater
 
#5 ·
You will need a 27mm socket to fit the flange nut and preferably a breakover bar for additional leverage. They can be really hard to get started turning because the whole output flange will turn even with it in gear. I put mine in 4WD and wedged a small prybar in between the ujoint and flange on the front output shaft to keep the rear flange from turning. Once it breaks loose it will be a breeze.

 
G
#9 ·
AH! Don't use an impact gun on your tcase drivceshaft flanges. This would not be a healthy thing for the gears inside. Basically the gears would be the parts taking the brunt of the rapid repetitive slamming of the impact. You might end up chipping a gear tooth.

Optimally, you should use a long torque wrench and do a slow controlled pull on the nut after you have undimpled the flange.

http://www.rocky-road.com