New Years Eve fun. Replaced Front Output shaft seal on my center diff after it started leaking a lot, leaving drops on the driveway. I originally bought parts to replace the front and rear seals and bearings only to find the front bearing is on backorder and since i wanted to knock this job out i ended up canceling the order and just ordering the front seal. Truck has 125k miles so the bearing should be (and was) fine anyways.
I could really only find a video of people doing it out of the truck, Lexusoverland (With patch) made a helpful video i used to plan this job.
I managed to get the front extension housing off inside the truck but it took a few tricks, Firstly there's one bolt on the back of the trans that i had to take out to get like 10mm worth of extra clearance, Then i realized i couldn't rotate the housing enough to get it off as the center diff lock slider rod was in the way, but i was able to engage the center diff lock and it pulled it back far enough that i could rotate the housing, and then finally the cat heat shield needed to be moved out of the way. This gave barely just enough room to get it out.
I did not use a press or any fancy tools, I was worried about how i was going to pull the gear off the shaft without buying the harbor freight puller, but i ended up stacking puller arms from an extra puller and it actually worked to get the gear off. I noticed in the lexusoverland video there was no reason to pull the bearing out, i smacked the shaft a few times on wood and it came free. Pry out the old seal, hammered the new one in, put the shaft back in, hammered it back in with a block of wood up to the same spot it was at before, and then used a brass drift and alternating hits to press the gear back on the shaft (worked very well)
Having that diff lock engaged made re-assembly even easier, as when the lock is off, the sliding collar actually falls off and dangles and lining it back up again is a chore, but if it's "locked" it slides it back on the output gear from the rear end and then it's all lined up.
Of course while i was under the truck, i noticed my front diff axle seal was leaking. I love this truck but holy smokes i've had to service almost every part of it since buying it, and it's got low miles! I would definitely be broke if i had to pay someone for labor...
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