Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Extension Housing Seal



See Figures 1, 2, 3 and 4

The extension housing seal on Samurai models and on 2WD Sidekick, Tracker, Sidekick Sport or X-90 models seals the slip-yoke of the driveshaft to the transmission housing. It can be accessed with the transmission still installed in the vehicle if you remove the driveshaft assembly.

For 4WD Sidekick, Tracker or X-90 models, the transfer case is bolted to the rear of the transmission and takes the place of the 2WD extension housing. So no external fluid seal is used on the transmission itself. If you discover fluid leaking from the rear of the transmission/transfer case assembly, the transfer case extension housing seal must be replaced. If fluid seeps from the seal between the transmission and transfer case housings, then the assembly should be removed and separated to determine and fix the problem. Under these rare circumstances, the gasket mating surfaces along with the rest of the transmission and transfer case housing assemblies should be carefully inspected for cracks or deformities.

But no matter which type of vehicle you are talking about, the extension housing seal (whether it is in the transmission or the transfer case) is replaced in the same manner.

Click image to see an enlarged view

Fig. Fig. 1: Remove the driveshaft for access to the extension housing seal (arrow)-this one's in the transfer case

Click image to see an enlarged view

Fig. Fig. 2: Use a small prybar or seal tool to carefully pry the old seal from extension housing ...

Click image to see an enlarged view

Fig. Fig. 3: ... then carefully drive the new seal into position using a suitably sized driver

  1. Block the front wheels of the vehicle, then raise and support the rear of the vehicle safely using jackstands. The rear of the vehicle is supported in this case to place the seal above the fluid-level line in the extension housing.
  3. Matchmark and remove the rear driveshaft from the vehicle.

Take care NOT to damage either the sealing surface of the extension housing or the output shaft during seal removal, or the new seal won't solve your problem.

  1. Using a small, suitable prytool or a specially designed seal remover (such as the one produced by Lisle®), carefully pry the old seal from the end of the extension housing.

If seal removal is especially difficult you can use a slide hammer with a special oil seal remover attachment, but this should not be necessary for most cases.

To install:
  1. Inspect the sealing surface of the output shaft and the extension housing for scores which might prevent sealing or small burrs which could tear a new seal as it was driven into position.
  3. Place a thin coating of high temperature lithium grease on the lips of the new seal.

Click image to see an enlarged view

Fig. Fig. 4: Use a suitably-sized driver and a plastic hammer to carefully install the new extension housing seal

  1. Position the seal at the opening of the extension housing and carefully drive it into position using a suitably sized seal driver and a plastic hammer. Drive the seal in until it is flush with the housing surface or just beneath the surface by no more than 0.04 in (1mm).
  3. Align and install the driveshaft. Be careful not to tear the new seal with the slip-yoke.
  5. If fluid was lost during the procedure or prior to it, make sure the vehicle is completely level. Then check the transmission fluid and top-off, as necessary.
  7. If not done already, remove the jackstands and carefully lower the vehicle.