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Bearings And Seals

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  1. Remove snap-ring that retains front output shaft front bearing in case. See Fig 1. Then remove bearing. Use hammer handle, or hammer and brass punch to tap bearing out of case.
  2. Install new front output shaft front bearing with Tool Handle C-4171 and Installer 8033-A with the tapered cone upward. See Fig 2.
    Fig 1: Front Output Shaft Front Bearing Snap-Ring Removal
    GC0017443Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT BEARING SNAP RING
    Fig 2: Install the Front Output Shaft Front Bearing
    GC0017444Courtesy of DAIMLERCHRYSLER CORP.
    1 - SPECIAL TOOL C-4171
    2 - SPECIAL TOOL 8033A
  3. Install front bearing snap-ring. See Fig 1.
  4. Remove front output shaft seal using an appropriate pry tool or slide-hammer mounted screw. See Fig 3.
  5. Install new front output shaft oil seal with Installer 6952-A. See Fig 4.
    Fig 3: Remove/Install Front Output Shaft Seal - Typical
    GC0025426Courtesy of DAIMLERCHRYSLER CORP.
    1 - OUTPUT SHAFT SEAL
    2 - PRY BAR
    Fig 4: Install Front Output Shaft Seal - Typical
    GC0025450Courtesy of DAIMLERCHRYSLER CORP.
    1 - INSTALLER 6952-A
    2 - TRANSFER CASE
  6. Remove input gear bearing with Tool Handle C-4171 and Remover C-4210. See Fig 5.
  7. Install snap-ring on new input gear bearing.
  8. Install new input gear bearing with Tool Handle C-4171 and Remover C-4210. Install bearing far enough to seat snap-ring against case. See Fig 6.
    Fig 5: Removing Input Shaft Bearing - Typical
    GC0017381Courtesy of DAIMLERCHRYSLER CORP.
    1 - SPECIAL TOOL C-4171
    2 - SPECIAL TOOL C-4210
    Fig 6: Seating Input Shaft Bearing
    GC0017382Courtesy of DAIMLERCHRYSLER CORP.
    1 - SNAP-RING
    2 - INPUT SHAFT BEARING
  9. Remove the 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. See Fig 7.
  10. Install new pilot bearing with Installer 8128 and Handle C-4171. See Fig 8.
    Fig 7: Remove Input Gear Pilot Bearing
    GC0017383Courtesy of DAIMLERCHRYSLER CORP.
    1 - DRIFT
    2 - INPUT GEAR
    Fig 8: Install Input Gear Pilot Bearing
    GC0017445Courtesy of DAIMLERCHRYSLER CORP.
    1 - HANDLE C-4171
    2 - INSTALLER 8128
    3 - INPUT GEAR
  11. Install new seal in front bearing retainer with Installer 7884. See Fig 9.
    Fig 9: Installing Front Bearing Retainer Seal
    GC0017385Courtesy of DAIMLERCHRYSLER CORP.
    1 - FRONT BEARING RETAINER
    2 - SPECIAL TOOL 7884
  12. Remove output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148. See Fig 10.
  13. Install new bearing with Tool Handle C-4171 and Installer 5066. See Fig 11. Lubricate bearing after installation.
    Fig 10: Removing Output Shaft Rear Bearing
    GC0017378Courtesy of DAIMLERCHRYSLER CORP.
    1 - REAR CASE
    2 - SPECIAL TOOL L-4454-1 AND L-4454-3
    3 - SPECIAL TOOL 8148
    Fig 11: Installing Output Shaft Rear Bearing
    GC0017379Courtesy of DAIMLERCHRYSLER CORP.
    1 - HANDLE C-4171
    2 - OUTPUT SHAFT INNER BEARING
    3 - INSTALLER 5066
  14. Install new seal in oil pump feed housing with Special Tool 7888. See Fig 12.
    Fig 12: Oil Pump Seal Installation
    GC0017386Courtesy of DAIMLERCHRYSLER CORP.
    1 - HOUSING SEAL
    2 - SPECIAL TOOL 7888
    3 - OIL PUMP FEED HOUSING
  15. Install new pickup tube O-ring in oil pump. See Fig 13.
Fig 13: Pickup Tube O-Ring Installation
GC0017446Courtesy of DAIMLERCHRYSLER CORP.
1 - PICKUP TUBE O-RING
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