Transfer Box Seals

[kmam]

My transfer box is leaking so I intend pulling the engine to get a good look at the source of the leak(s) and replace the seals. I have TM 9-2320-218-34 but would appreciate any advice based on experience doing this job.

[rickf]

Beer, lots of beer. And keep the kids away due to foul language.
Just kidding, once it is out of the vehicle it is not all that bad. The original military seals can be a bear to get out since they are so wide in the hole. I have found that the easiest way is to just fold one side in with an old screwdriver and hammer. then it will come out much easier. If you use regular seal pullers you risk gouging the housing because the seals really hang on. The rear output seal is easy since the seal housing comes off and you can punch the seal out from the inside on the bench. The little tiny seal for the shift rod is the one that is a pain since it is too small to get hold of it from the outside.

[Hambone]

It's not bad, rear is easy, front seal will give you a little problem, not much room if you're doing with tranny still in the jeep. As Rick said, take a screwdriver or small chisel and relieve the seal from the outer edge, be careful not to damage the inside where the seal seats. Here is a pic of the front seal, you will see it takes a little effort. As for the wear sleeves, remove the yoke from the shaft, put the yoke in the freezer overnight, this will make pressing the sleeve on much easier. You can do this in a vise or press, I usually put a block of wood on top of the sleeve when I press them on, the sleeve does not have to be fully seated, just press them to the end of the yoke.

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