Rear Output Shaft Seal: Installation

WARNING: This page is about a different variant/trim than selected.

Apply liberal quantity of petroleum jelly to new rear seal and to output shaft. Petroleum jelly is needed to protect seal lips during installation.
Slide seal onto Seal Protector 6992. Slide seal protector and seal onto output shaft.

Fig 1: Installing Output Shaft Seal & Protector
Courtesy of DAIMLERCHRYSLER CORP.
Slide Installer C-4076-B onto seal protector with the recessed side of the tool toward the seal. Drive seal into rear bearing retainer with Installer C-4076-B and Handle MD-998323.

Fig 2: Installing Rear Seal
Courtesy of DAIMLERCHRYSLER CORP.

NOTE: Vehicles built with a 4.0L engine and a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.

Install a new output shaft rear slinger with Installer 8408, if the vehicle is not equipped with an output shaft damper.
If the vehicle is equipped with an output shaft damper, install the output shaft damper as follows:
1. Position the damper weight on the output shaft. Start the damper onto the output shaft chamfer, being careful to keep the weight square to the output shaft. (Fig. 92)
  
  Fig 3: Positioning Damper On Output Shaft
  Courtesy of DAIMLERCHRYSLER CORP.
2. Position the driver portion of Installer 8422 onto the damper, making sure the legs of the damper are positioned through the slots of the damper.
  
  Fig 4: Positioning Driver Installer 8422
  Courtesy of DAIMLERCHRYSLER CORP.
3. Thread the puller screw of Installer 8422 into the output shaft by hand only. Make sure the screw is fully threaded into the output shaft.
4. Using a wrench to hold the pulling screw stationary, turn the pulling screw nut until the driver legs contact the rear face of the transfer case rear retainer. When the legs contact the retainer, the damper is properly positioned on the output shaft.
  
  Fig 5: Installing Damper
  Courtesy of DAIMLERCHRYSLER CORP.
Install boot on output shaft slinger, or output shaft damper, and crimp retaining clamp with tool C-4975-A.

Fig 6: Installing Slinger Boot (Typical)
Courtesy of DAIMLERCHRYSLER CORP.
Slide the slip yoke on the transmission/transfer case output shaft. Align installation reference marks at the axle yoke and install the propeller shaft.
Tighten the U-joint strap/clamp bolts at the axle yoke to 19 N.m (14 ft. lbs.).
Crimp clamp with Clamp Tool C-4975A to hold dust boot to propeller shaft yoke.
Remove support and lower the vehicle.