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replace a rear seal on a np241

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I have a 1989 k5 with a np241 transfer case and about a week ago i noticed the rear output seal was leaking. Now it is getting bad, and I know it needs taken care of. I have never done anything with a transfer case and I am no mechanic, but do not have the funds to have someone else do it.

So I am looking for some step by step instructions from someone with experience or a good website. This is my only vehicle and i drive it everyday, so, i dont want to try to tear into it without knowing what I am doing!

Thank you for your time.
 
It is really quite simple. It should hat a "hat" type seal on it. Remove the drive shaft (after blocking the tires - safety first). Use a small chisle and tap it between the lip of the seal and the tailshaft. after working around the seal lip, you should be able to pull the deal out with vise grips or pliers. Tap the new seal in place using a hammer. If you have never installed a seal of any kind, just remember to work it in gradually by working arounf the circumference of the seal. Put some tranny fluid on the rubber of the new seal. Before installing the drive shaft, make sure the sealing surface is clean so it will not damage the new seal. I use emery cloth for this. Install the drive line and check the fuild level.
 
Remove the two u-joint straps holding the rear u-joint to the rear differential. Put a large screw driver between the yoke and the u-joint and pry the u-joint caps from the yoke. be careful not to drop the caps and spill the needle bearings all over the place. Wrap the u-joint with some tape and pull the drive shaft out of the t-case tail shaft.

Note: be sure the transmission is in neutral before taking the rear u-joint out of the rear yoke!
 
AKbigsub said:
It is really quite simple. It should hat a "hat" type seal on it. Remove the drive shaft (after blocking the tires - safety first). Use a small chisle and tap it between the lip of the seal and the tailshaft. after working around the seal lip, you should be able to pull the deal out with vise grips or pliers. Tap the new seal in place using a hammer. If you have never installed a seal of any kind, just remember to work it in gradually by working arounf the circumference of the seal. Put some tranny fluid on the rubber of the new seal. Before installing the drive shaft, make sure the sealing surface is clean so it will not damage the new seal. I use emery cloth for this. Install the drive line and check the fuild level.
Click to expand...

AJMBLAZER said:
Just to state the obvious make sure the tires are chocked and the parking brake is on when you do this.

There's a bushing that the tailshaft rides in you might want to replace. I had a little fun with that this past summer.
http://coloradok5.com/forums/showthread.php?t=256305&highlight=seal
Click to expand...

It's always nice to hear other people being safety minded too. I forgot to mention the parking brake because mine is not hooked up:doah:
 
Like mentioned above, I would do the bushing too. If you do the bushing go to a GM dealer to get the new one.
 
wayne said:
Like mentioned above, I would do the bushing too. If you do the bushing go to a GM dealer to get the new one.
Click to expand...
Quoted for truth. The NAPA, Advanced Auto, and AutoZone bushings all fell straight through my housing.
 
When installing the new seal use a block of 2x4 between the hammer and the seal. It lets you knock it in evenly and not smashing one side.
 
Yep. The seal worked perfectly but the bushing was undersized.
The GM part was only like $8 anyways.
 
I usually use a 6 inch regular screwdriver and a hammer. Gently, pound the screwdriver through the metal part of the seal. Then use it like a pry bar to "pry" the seal out. Being careful not to gouge the inside of the Tcase.
If they get particularly bitchy, I'll use a chisel and gently "Pacman" the whole seal. They usually fall out once you get it pacmanned enough.
 
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