Chrysler Full-Size Trucks 1997-2000 Repair Guide

Front Output Shaft Seal

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REMOVAL & INSTALLATION



NV231, NV242
  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the front driveshaft.
  4.  
  5. Remove the driveshaft yoke from the output shaft.
  6.  
  7. Place a drip pan beneath the transfer case.
  8.  
  9. Pry out the front seal with a hooked tool or prybar.
  10.  

To install:

  1. Grease the lips of the new seal and drive it straight in until it is seated. The garter spring on the seal faces towards the case.
  2.  
  3. The remainder of the procedure is the reverse of removal.
  4.  



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Fig. Prying out the front transfer case seal-NV231, NV242

NV231HD, NV241LD
  1. Raise and safely support the vehicle securely on jackstands.
  2.  
  3. Remove the front driveshaft.
  4.  
  5. Remove the companion flange from the transfer case output shaft. Use a puller to free it from the shaft, if necessary.
  6.  
  7. Place a drip pan beneath the transfer case.
  8.  
  9. Remove the flange rubber seal from the shaft.
  10.  
  11. Pry out the front seal with a hooked tool or prybar.
  12.  

To install:

  1. Grease the lips of the new seal and drive it straight in. The garter spring on the seal faces towards the case.
    1. On the NV231HD, drive the seal in until it is seated.
    2.  
    3. On the NV241LD, drive the seal in until it is recessed 0.080-0.100 in. (2.0-2.5mm) below the top edge of the seal bore.
    4.  

  2.  


WARNING
The seal could loosen or become cocked if not fitted to the correct depth.

  1. Install the flange rubber seal.
  2.  
  3. Install the companion flange. Tighten the nut to 130-200 ft. lbs. (176-271 Nm).
  4.  
  5. The remainder of the procedure is the reverse of removal.
  6.  



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Fig. Removing the companion flange



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Fig. Removing/installing the flange rubber seal



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Fig. Correct installation of the output shaft seal

 
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