Dual seal and parking brake upgrade (1 Viewer)

[FJmaine]

I couldn't find a clear set of instructions for upgrading the rear output shaft seal to the Valley Hybrid dual seal housing. This is my attempt to create one. Thanks for all the help for @orangefj45 working through this.
What came in the package:
-New dual seal housing
-Paper gasket
-2 new crush rings for drain and fill
-2 o-rings for speedo bullet (large and small)
-4xM8 Allen bolts (note** one bolt is shorter than the others)
-Stake nut

I also used Permatex gear oil gasket maker

In the classic "while I'm here" I rebuilt my parking brake as well with Valley hybrid parts.


Edit**- Follow these steps at your own risk. All information here worked for me, but may not work for you (including torque values)

 

[FJmaine]

First things to do are drain the transfer case oil and remove the drive shaft. Its recommended to remove the nuts on the transfer case end first so the drive shaft isn't hanging while trying to remove them. Next up is remove the stake nut. This should just wind off as the steel is fairly soft.

Then remove the parking brake drum.

 

[FJmaine]

If you are not rebuilding the parking brake, ignore this.
First, remove the springs and adjusting mechanism, then compress the spring on the cable and pull the cable out of the lever arm. Then remove the retaining clip. This is a soft steel clip that needs to be opened up and pulled off. Once this is removed, the cable can be pulled out of the brake assembly.
This can be done with the brake assembly mounted our unbolted. I did it with it unbolted so I had more freedom. Not sure if this made it better or worse.

 

[FJmaine]

Remove the parking assembly

 

[FJmaine]

Remove the speedo cable and unbolt the seal housing. With the housing on a bench. work on getting the speedo bullet out as this will have to be transferred to the new housing. I used PB Blaster, a little heat, a small pry bar and gentle tapping, and lots of patience to encourage the speedo bullet to come out. It clearly hasn't been touched in almost 50yrs.

 

[FJmaine]

Clean and rebuild the speedo bullet.

The small o-ring is a little more tricky. It is about halfway down inside the bore of the bullet. Use a pick to reach in and gently dislodge the o-ring, then pull it out.

Once I got it out, I greased up the new one and installed it. I pushed the o-ring in so it was fully contained in the inner bore, then used a drift to push it in farther. It was easier getting it in than I expected.

Final step is to grease up the speedo gear shaft and gently work it in through the new o-ring.

 

[FJmaine]

I had to clean a little paint out of the bore for the speedo bullet, then installed it once it fit properly.
I put the gasket material on both sides of the paper gasket, cleaned all mating surfaces, then installed the new housing. The bolts should be torqued to 20ft-lbs.

Next step is reinstall the parking brake assembly. The short allen bolt that is provided in the kit goes in the hole near the speedo bullet. Torque these to 15-20ft-lbs

Install the parking cable, the clip, then the cable to the lever arm.
Install the drum, washer, and stake nut. Torque to 60-65ft-lbs, then stake the nut to the shaft. I sued a small sledge and a cold chisel for staking.

 

[Green Bean]

Great pics and write--up. Thanks for posting.

 

[70fj40]

Wow. Great step by step instruction. Makes me believe even a 1 banana like me could tackle that job.