Rear output shaft leak

[Gumby]

Yesterday I decided to get rid of my output shaft seal leak I have had since hitting my driveshaft on some rocks while wheeling. I made sure it wasn't the speedo gear o-ring, then tore into the tailshaft housing. You can't just unbolt the pinion, you have to remove a big chunk off of the back of you transfer. Then it's fun with snap rings time. Of course, my snap ring pliers are in my trail box so I didn't get it all the way disassembled last night and had to call the wife for a ride home. :-[

Pics to follow.

 

[landtank]

My seal started to leak right after the lift. Got the new seals and finally some time, crawled under and the leak had stopped. And yest I checked the fluid level :. Been fine for about a year now.

 

[Gumby]

Definately the job for good snap ring pliers. Not the kind with the little pins that fit in little holes, but one with a big flat area exactly like the ones for doing hub snap rings.

The first one is doable without, but a major PIA. Much easier with the right tool. All you have to do to get to it is remove the tail section of the transfer case. The bolts are hurt-your-back tight and are of different lengths, but I had no problems putting them back in the right places. The speedo unit, two plugs on top of the case and the ground strap must come off, with of course the driveshaft. In order to seperate the cases, I had to put a jack under the tailshaft and lower the truck on the hoist. They are stuck together pretty darn good.

oops. No file attachments. no pics for you.

The second snap ring holds in the speedo gear and the third holds the shaft in place. Once they are all out, you can push the output shaft and flange out of the back of teh case. Then you can change the seal.

All in all about a two hour job with the right equipment. If it wasn't messing up my driveway I'd of just let it drip.

 

[landtoy80]

One note:
Clean the top of the t-case off good as junk will fall into the case if you don't.