Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide

Input and Output Shaft Seals

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3

  1. Raise and support the vehicle safely using jackstands. Lift either the front or the rear of the vehicle, depending on which seal is being replaced, so that the seal which is being worked on will be angled upward. This should help minimize the amount of gear oil which is lost during the procedure.
  2.  
  3. Matchmark and remove the driveshaft from the vehicle for access to the seal.
  4.  
  5. For Samurai models, use a special flange holding tool (such as Suzuki's 09930-40113 or equivalent), then loosen and remove the universal joint flange nut.
  6.  

For the Samurai, if a special tool is not available one can be made from a VERY sturdy piece of stock, drilled to match 2 of the bolt holes in the flange. The stock can then be bolted to the flange and used as a lever to keep it from turning.


WARNING
Take care NOT to damage either the sealing surface of the transfer case housing or the 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.
  2.  

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 shaft and the transfer case for scores which might prevent sealing or small burrs which could tear a new seal as it was driven into position.
  2.  
  3. Place a thin coating of high temperature lithium grease on the lips of the new seal.
  4.  



Click image to see an enlarged view

Fig. Fig. 1: Remove the driveshaft for access to the extension housing seal (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. Position the seal at the opening of the transfer case 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 or just below the housing surface.
  2.  
  3. For the Samurai, install the universal joint flange and secure using the retaining nut. Tighten the nut to 80-108 ft. lbs. (110-150 Nm).
  4.  
  5. Align and install the driveshaft. On all models except for the Samurai, be careful not to tear the new seal with the slip-yoke.
  6.  
  7. If fluid was lost during the procedure or prior to it, make sure the vehicle is completely level. Then check the transfer case fluid and top-off, as necessary.
  8.  
  9. Remove the jackstands and carefully lower the vehicle.
  10.  

 
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