Bearings And Seals

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

CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.

Remove the front output shaft seal from case with pry tool.

Fig 1: Removing Front Output Seal (Typical)
Courtesy of DAIMLERCHRYSLER CORP.
Remove the front output shaft bearing retaining ring with screwdriver.

Fig 2: Removing Front Output Shaft Bearing Retaining Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove bearing with Tool Handle C-4171 and Tool 5065.

Fig 3: Removing Output Shaft Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install front output shaft front bearing in case with Tool Handle C-4171 and Installer 5064.

Fig 4: Installing Front Output Shaft Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install output shaft front bearing retaining ring. Start ring into place by hand. Then use small screwdriver to work ring into case groove. Be sure ring is fully seated before proceeding.

Fig 5: Installing Output Shaft Front Bearing Retaining Ring
Courtesy of DAIMLERCHRYSLER CORP.
Install new front output seal in front case with Installer Tool 8143-A as follows:
1. Place new seal on tool. Garter spring on seal goes toward interior of case.
2. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool bottoms against case.
  
  Fig 6: Installing Front Output Seal (Typical)
  Courtesy of DAIMLERCHRYSLER CORP.
Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148.

Fig 7: Removing Output Shaft Rear Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install new bearing with Tool Handle C-4171 and Installer 5066. The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer.

Fig 8: Installing Output Shaft Rear Bearing
Courtesy of DAIMLERCHRYSLER CORP.

Fig 9: Identifying Output Shaft Rear Bearing Installation Depth
Courtesy of DAIMLERCHRYSLER CORP.
Using Remover C-4210 and Handle C-4171, drive input shaft bearing from inside the annulus gear opening in the case.

Fig 10: Removing Input Shaft Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install locating ring on new bearing.
Position case so forward end is facing upward.
Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing locating ring must be fully seated against case surface.

Fig 11: Seating Input Shaft Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer.

Fig 12: Removing Input Gear Pilot Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Install new pilot bearing with Installer 5065 and Handle C-4171.

Fig 13: Installing Input Gear Pilot Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Remove front bearing retainer seal with suitable pry tool.
Install new front bearing retainer seal with Installer 7884.

Fig 14: Installing Front Bearing Retainer Seal
Courtesy of DAIMLERCHRYSLER CORP.
Remove seal from oil pump housing with a suitable pry tool
Install new seal in oil pump housing with Installer 7888.

Fig 15: Installing Oil Pump Seal
Courtesy of DAIMLERCHRYSLER CORP.
Remove rear retainer bearing with Installer 8128 and Handle C-4171.
Install rear bearing in retainer with Handle C-4171 and Installer 5064.

Fig 16: Installing Rear Bearing In Retainer
Courtesy of DAIMLERCHRYSLER CORP.