Output shaft to transfer case seal

[SrKegler]

Need some help fast guys. I read all the articles about replacing this seal with the transmission in the car. I'm getting the car ready for sale and want to make sure everything is perfect on it.

Problem is, all the posts I searched says you can replace the seal in the transmission with it still in the car. I've got my transfer case off but cannot figure out how to get the old seal out, let alone get the new one in. My new seal will not fit over the splines, the flywheel get in the way. Need some guidance on how you guys were able to accomplish this without pulling the transmission.

 

[kchaazz]

Im not sure you can do it with the shaft in the transmission. What you may need to do is drain the oil from the trans, remove the end case off the transmission, then you will see the viscous coupler. There is a snap ring that you must remove from the VC, then you can put a punch in the little indent on the end of the shaft, and gently tap it out with a hammer. There are two little balls that hold the shaft and VC together that you will need to be careful not to lose. Once the output shaft is out, you can replace the seal. Once the seal is in, slide the shaft back in, then put heavy grease onto the two balls and put them in their place, the grease will help hold the balls in place while you tap the VC with a deadblow hammer to set it. Replace the snapring, clean the flange on the transmission side and on the plate, run a .125" bead of black RTV along the frange on the trans side, replace the plate and evenly torque the bolts to...33 FT LBS I believe. Wait 24 hours for the RTV to cure before refilling with fluid.
Here are a couple pics of what youll be dealing with. Still far better than pulling the trans, and not too bad if youre comfortable with it.

 

[2gmitsueclipse]

The above post is good info. To add to it, there is only one detent ball for the output shaft. Once you open the case, also pay attention to the orientation of the wave spring for reverse because it needs to be put back on the same way. I would just take some pics when you open the case to see where where things should go when you reassemble. Are sure you pry at the appropriate spots when trying to separate the endcase.

As far as the seal goes, I carefully ran a drywall screw into the seal. Just enough to pierce the metal in the seal. I then used a pair of pliers to pull the screw. This method worked for me and caused no damage on the sealing surface of the trans. For reference on where to have the screw, look at the inside of the new seal and you should notice it is reinforced with metal. Be very careful when doing this. My first time doing this Job took about 1.5 hours.

 

[SrKegler]

Thanks guys. All the other searches said it could be done just by removing the xfer case. Guess it was just kids talking thru their butts. I didn't really want to go that route, but it's easier than pulling the trans. Once I get the shaft out, shouldn't be any problem getting the old seal out.