Transfer Case Rear Output Shaft Seal Replacement Issues

[j_2000_limited]

After noticing gear oil leaking from my transfer case on my 2000 limited 4wd, I have been diying the seal replacement (with no access to a lift). I have successfully replaced the seal for the front output shaft as well as both companion flange seals, but have been struggling to seat the rear and in my attempt I damaged the new seal while trying to tap it in due to how snug it was. I am purchasing a 2nd new seal from the dealer tomorrow but need a new installation technique.

It appears as though there is a small amount of corrosion / buildup on the sealing surface inside the transfer case and I believe that is making my life more difficult. Is it possible / advisable to clean the surface with some emory cloth prior to my next seal installation attempt?

Additionally, I have read online that some folks put the seal in the freezer prior to the install to shrink it slightly and so I will probably try that as well.

Those ideas aside, do folks who have experience with stubborn seals have any advice?

Cheers!

 

[grabba]

The freezing could be something to try, But the corrosion/build-up is probably your issue here. Just be careful when cleaning it not to go over board

 

[grabba]

Also are you using a proper seal install tool?

 

[j_2000_limited]

Also are you using a proper seal install tool?

I do not have a manufactured one no, but I 3d printed my own (I recognize that the increased elasticity will reduce my hammer hits effectiveness). Honestly the seal fit was so tight that I do not believe it would have helped, the friction was simply too much to overcome.

 

[vegask]

I do not have a manufactured one no, but I 3d printed my own (I recognize that the increased elasticity will reduce my hammer hits effectiveness). Honestly the seal fit was so tight that I do not believe it would have helped, the friction was simply too much to overcome.

Care to share the 3d file? I have a case I need to work on this weekend.