Transfer Case Shift Shaft Seal: A Pictorial Guide (1 Viewer)

[Perovich]

There are a few threads about this already, but I couldn't find a step-by-step guide on this job. So I decided to make one for anyone else who may need one!
If I remember correctly, the Toyota FSM states you should partially disassemble the transfer case to do this job, but that's not necessary. So for anyone else who may be so inclined --

You will need:
Ratchet (long-handled preferably)
15mm socket (deep socket preferably)
14mm wrench (stubby and/or ratcheting preferably)
Flat-head screwdriver or pry tool
Hammer and soft punch or seal installation tool
Shop towels and de-greaser

Estimated time:
45 minutes

Optional:
Beer

1.) Order the following parts (90311-22005 / 36318-60020):

2.) Remove the dust boot from the shaft (if it's leaking, expect gear oil to come out):

3.) Locate the nut securing the shift shaft control rod onto the transmission assembly:

4.) Remove the 15mm nut (a long-handled flex-head ratchet is ideal):

5.) Locate and remove the 14mm nut securing the shift shaft control rod retainer to the top of the transmission assembly (a stubby 14mm ratcheting wrench is ideal):

 

[Perovich]

6.) Remove the now-loose retaining bracket, and shimmy the shift shaft control rod away from the mounting stud to create enough clearance between the shift shaft and plastic bushing to safely remove and install the new seal:

7.) Remove and replace the seal. Be sure to clean the shaft of all oil and debris. Take note that the seal will bottom out inside of the transfer case assembly, and will allow enough gap between the lip of the seal and the transfer case surface for the boot to remain secure:

8.): Ensure that the dust boot is fully seated onto the shift shaft seal (a 45* pick tool helps):

9.) Reverse your previous steps. Take care with the shift shaft control rod stud. There are two bushings on either side of the stud that may need some assistance in lining up prior to reinstallation:

10.) Fill up your transfer case and transmission to the appropriate levels (remove the fill plug first!), and enjoy your new leak-free transfer case: