This job is a real PITA. Took me 8 hours including trying to find some snapring pliers man enough for the job (it took me 2 days to do the hubs for comparison, yes im slow but this time i reckon i could change the rear tc oil seal in half that time). The pliers are important as the usual snapring pliers with attachments do not spread far enough and the attachments get in the way for the deeper snap rings. you also need a big hammer and a deep socket, or similar, you dont mind using to knock the shaft out of the bearing. you could use a press of course but a big hammer is will do fine. you will also need some liquid gasket stuff to seal the TC when asembling.
Basicaly to change this cheap 8 or 9 quid seal you need to do the following:
1 remove rear prop from TC
2 remove rear transfer case extension housing (the rear part of the TC) oh and drain the oil first
3 now working on the rear extension housing remove the first snap ring
4 remove the viscous coupling
5 remove the separator and oil pump plate by undoing 3 bolts
6 remove speedometer form the housing (now you can poke a screwdriver in through here to aid snapring removal)
7 remove snap ring 2
7 remove the speedometer drive gear
8 remove the final snapring
9 hammer out the rear output shaft
10 remove the oil seal yay!
11 remove dust deflectors from shaft and rear output shaft and replace (this is optional, they are cheap but difficult to hammer the new ones back in place as they bend easily. you will need to find something that will distribute pressure on them evenly when hammering in something flat will not do i used a very tough cardboard tube)
12 if you want to change the bearing now is the time to do it (i didnt bother as it seemed in great condition, also i had no idea the 2 were linked) thats after you remove another snapring.
reassembly is the reverse of removal.
enjoy
