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replacing output shaft seal

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You mean the seal that goes around the shaft that goes into the transfer case, right?

It's pretty easy, first remove the downpipe, then remove the transfer case. The seal and the shaft are right there. You'll have to drain the tranny fluid. Clean the area so you don't get dirt inside, pry the seal out being carefull not to scratch or gouge the shaft or the case. Make sure the mating surfaces for the seal are very clean. Carefully push the new seal in. I like to use a light coating of RTV on the outer edges of seals to make it easier to push in, and it also makes a very secure seal. Make sure it's straight and not too deep. There isn't a stop for the seal, so don't push it in too far.
 
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