‹

Seals and Gaskets

Transmission and Drivetrain › Automatic Transmission/Transaxle
Unified entry — merged from multiple cross-listed pages in the original manual.

Parts

PartOutput Shaft Seal
ManufacturerCHY
OEM part #5013019AA
Price$21.60
NotesOrder By Description.
PartAxle Seals
ManufacturerCHY
OEM part #5066066AA
Price$20.25
PartPinion Seal
ManufacturerCHY
OEM part #68004072AA
Price$26.25
PartAxle Seals
ManufacturerCHY
OEM part #52111198AB
Price$20.50

Labor

Replace — Output Shaft Seal — Front4.9 hr
Warranty 0.0 hrSkill B
Rear0.6 hr
Warranty 0.0 hrSkill B
Replace — Front Axle — Cover Gasket1.7 hr
Warranty 0.0 hrSkill B
Output Shaft Seal — Right Side1.2 hr
Warranty 0.0 hrSkill B
Pinion Seal1.3 hr
Warranty 0.0 hrSkill B
Rear Axle — Pinion Seal0.6 hr
Warranty 0.0 hrSkill B
Replace — Extension Housing Seal2.4 hr
Warranty 0.0 hrSkill B
Procedures
MP1522 Transfer Case — Rear Output Shaft Seal - Removal6 steps
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  1. Remove the rear propeller shaft. Drive Shaft - Removal
  2. Using Holder (1), remove the rear companion flange (2) nut.
  3. Remove the rear output shaft flange from the output shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output shaft flange. Figure 2 - DAMPER
  4. Remove the damper bolts (2) and damper (1), (if equipped).
  5. Remove the rear output shaft seal with a suitable pry tool or a screw mounted in a slide hammer. Figure 3 - REAR RETAINER
  6. Remove the rear cover bolts (3) and the rear cover (2), from the rear transfer case housing (1).
MP1522 Transfer Case — Rear Output Shaft Seal - Installation8 steps
ℹ NOTE
Lubricate all seals with MOPAR(R) ATF+4 prior to installation.
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  1. Install a new rear output shaft seal (3) into the rear cover with Installer (2) and handle (1).
  2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear housing as shown (2). Keep sealer bead width to maximum of 3 mm (1/8 inch). Do not use excessive amount of sealer as excess could be displaced into the oil pump. Figure 3 - REAR RETAINER
  3. Install the bolts (3) holding the rear cover (2) onto the rear housing (1). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 Nm (20 ft.lbs.). Figure 4 - DAMPER
  4. Install the damper (1), (if equipped),and damper bolts (2) into the case. Tighten the damper bolts to 27 Nm (20 ft. lbs.).
  5. Install the rear output shaft flange onto the output shaft.
  6. Using Holder (1), install the rear companion flange (2) nut. Tighten the bolts to 122-176 Nm (90-130 ft.lbs.).
  7. Install the rear propeller shaft. Drive Shaft - Installation
  8. Check the transfer case fluid level. MP1522 Transfer Case - Fluid Drain And Refill Correct as necessary.
MP1522 Transfer Case — Input Shaft Seal - Removal2 steps
  1. Remove the transfer case from the vehicle MP1522 Transfer Case - Removal
  2. Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
MP1522 Transfer Case — Input Shaft Seal - Installation3 steps
ℹ NOTE
Lubricate all seals with MOPAR(R) ATF+4 prior to installation.
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  1. Install the new input shaft seal with Installer and Handle.
  2. Install the transfer case into the vehicle MP1522 Transfer Case - Removal
  3. Check the transfer case fluid MP1522 Transfer Case - Fluid Drain And Refill.
MP3022 Transfer Case — Front Input Shaft Seal - Removal2 steps
  1. Remove the transfer case from the vehicle. MP3022 Transfer Case - Removal
  2. Remove the front input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
MP3022 Transfer Case — Rear Output Shaft Seal - Removal6 steps
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  1. Remove the rear propeller shaft. Drive Shaft - Removal
  2. Using Holder (1), remove the rear companion flange (2) nut.
  3. Remove the rear output shaft flange from the output shaft. If necessary, use a suitable 2 or 3 jaw puller to remove the output shaft flange.
  4. Remove the damper bolts and the damper from the transfer case, (if equipped).
  5. Remove the rear output shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
  6. Remove the rear cover bolts and the rear cover from the transfer case.
MP3022 Transfer Case — Rear Output Shaft Seal - Installation8 steps
ℹ NOTE
Lubricate all seals with MOPAR(R) ATF+4 prior to installation.
ℹ NOTE
Do not use excessive amount of sealer as excess could be displaced into the oil pump. Keep sealer bead width to maximum of 3 mm (1/8 inch).
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  1. Install a new rear output shaft seal into the rear cover with Driver Handle and inverted Installer.
  2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to one of mating surfaces of the rear cover or rear transfer case housing. Install the rear cover being certain the tabs on the rear cover align with the tabs on the rear housing.
  3. Install the rear cover bolts. Tighten the rear cover bolts in a crisscross pattern to 27 Nm (20 ft.lbs.).
  4. Install the damper, (if equipped), and the damper bolts onto the transfer case. Tighten the damper bolts to 27 Nm (20 ft.lbs.).
  5. Install the rear output shaft flange onto the output shaft.
  6. Using Holder (1), install the rear companion flange (2) nut. Tighten the nut to 122-176 Nm (90-130 ft.lbs.).
  7. Install the rear propeller shaft. Drive Shaft - Installation
  8. Check the transfer case fluid level. Correct as necessary MP3022 Transfer Case - Fluid Drain And Refill.
MP3022 Transfer Case — Front Input Shaft Seal - Installation3 steps
ℹ NOTE
Lubricate all seals with MOPAR(R) ATF+4 prior to installation.
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  1. Using Driver handle (1) and seal Installer (2) install the front input shaft seal.
  2. Install the transfer case into the vehicle. MP3022 Transfer Case - Installation
  3. Check the transfer case fluid. MP3022 Transfer Case - Fluid Drain And Refill Correct as necessary.
Front Axle - 186FIA — Axle Shaft Seal - Removal3 steps
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  1. Remove haft shafts.
  2. On the right side, remove axle shaft (1) with Remover (2) and Slide Hammer.
  3. Remove shaft seal (1) from axle with Remover (2) and a Slide Hammer.
Front Axle - 186FIA — Pinion Seal - Removal8 steps
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  1. Remove brake calipers and rotors.
  2. Remove propeller shaft.
  3. Rotate pinion gear several times and verify the pinion rotates smoothly.
  4. Record pinion torque to rotate (1) with an inch pound torque wrench (2).
  5. Hold pinion flange (1) with Flange Holder (2) and remove pinion nut.
  6. Mark a line on the pinion shaft and flange for installation reference.
  7. Remove pinion flange with Puller (1) and Flange Holder (2).
  8. Remove pinion seal with a seal puller.
Front Axle - 186FIA — Pinion Seal - Installation8 steps
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  1. Apply a light coating of gear lubricant on the lip of pinion seal. Install with Installer (1) and Handle (2).
  2. Position flange on the pinion shaft with the reference marks aligned.
  3. Install flange with Installer (1) and Screw (2).
  4. Install a new nut on the pinion gear. Hold pinion flange (1) with Flange Holder (2) and tighten pinion nut to 217 Nm (160 ft. lbs.).n Note: Do not exceed minimum tightening torque 217 Nm (160 ft. lbs.) at this point.
  5. Rotate pinion several times and verify pinion rotates smoothly.
  6. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotating should be equal to recorded reading plus 0.56 Nm (5 in. lbs.).If rotating torque is low, tighten the pinion nut in 6.8 Nm (5 ft. lbs.) increments until proper rotating torque is achieved. CAUTION: If maximum tightening torque is reached 352 Nm (260 ft. lbs.) prior to reaching required rotating torque, the collapsible spacer may have been damaged.Never loosen pinion nut to decrease pinion rotating torque and never exceed specified preload torque. Failure to follow these instructions will result in damage.
  7. Install brake rotors, calipers and propeller shaft.
  8. Fill differential with gear lubricant.
Front Axle - 186FIA — Axle Shaft Seal - Installation3 steps
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  1. Apply a light coat of lubricant on the lip of the shaft seal.
  2. Install new shaft seal with Installer (1) and Handle (2).
  3. Install right axle shaft and half shafts.
Rear Axle - 8 1/4 — Axle Shaft Seal - Removal2 steps
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  1. Remove axle shaft (1) from axle tube (2).
  2. Remove axle shaft seal (1) from axle tube (2) with seal puller.
Rear Axle - 8 1/4 — Pinion Seal - Removal11 steps
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  1. With vehicle in neutral, position vehicle on hoist.
  2. Remove wheel and tire assemblies.
  3. Mark a reference line across the axle flange (1) and propeller shaft flange (2).
  4. Remove companion flange bolts and remove propeller shaft.
  5. Remove brake calipers and rotors to prevent any drag.
  6. Rotate companion flange three or four times and verify flange rotates smoothly.
  7. Record pinion torque to rotating (1) with an inch pound torque wrench (2) for installation reference.
  8. Hold pinion flange (1) with Holder (2) and remove pinion nut.
  9. Mark a line across the pinion shaft and flange for installation reference.
  10. Remove pinion flange (1) with Puller (2).
  11. Remove pinion seal with a seal puller.
Rear Axle - 8 1/4 — Pinion Seal - Installation8 steps
ℹ NOTE
Do not exceed the minimum torque 285 Nm (210 ft. lbs.) when installing the pinion nut at this point.
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  1. Apply a light coating of gear lubricant on the lip of pinion seal.
  2. Install new pinion seal with Installer (1) and Handle (2).
  3. Install flange on the pinion shaft with the reference marks aligned.
  4. Install flange (1) with Installer (2).
  5. Install new pinion nut. Hold flange (1) with Holder (2) and tighten pinion nut to 285 Nm (210 ft. lbs.). Rotate pinion several revolutions to ensure the bearing rollers are seated.
  6. Measure pinion torque to rotate (1) with an inch pound torque wrench (2). Pinion torque to rotating should be equal to recorded reading plus an additional 0.56 Nm (5 in. lbs.).If pinion torque to rotate is low, tighten pinion nut in 6.8 Nm (5 ft. lbs.) increments until pinion torque to rotating is achieved. CAUTION: Never loosen pinion nut to decrease pinion bearing rotating torque. If pinion torque to rotating is exceeded, a new collapsible spacer must be installed. Failure to follow these instructions will result in damage to the axle.
  7. Install propeller shaft (1) with axle flange (2) installation reference marks aligned.
  8. Install rear brake components.
Rear Axle - 8 1/4 — Axle Shaft Seal - Installation3 steps
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  1. Remove any old sealer/burrs from axle tube.
  2. Coat new seal lip with axle lubricant and install seal with Installer (1) and Handle (1).
  3. Install axle shaft (1) in axle tube (2).
Adapter Housing Seal - Removal2 steps
  1. Remove the transfer case Removal and Replacement.
  2. Using a screw mounted in a slide hammer, remove the adapter housing seal.
Extension Housing Seal - Installation3 steps
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  1. Place seal in position on overdrive housing.
  2. Drive seal into overdrive housing with Seal Installer (1)(Figure 1).
  3. Carefully guide propeller shaft slip yoke into housing and onto output shaft splines. Align marks made at removal and connect propeller shaft to rear axle pinion yoke.
Adapter Housing Seal - Installation2 steps
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  1. Install a new adapter housing seal with Universal Handle and Seal Installer.
  2. Install the transfer case Removal and Replacement.
Extension Housing Seal - Removal4 steps
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  1. Raise vehicle.
  2. Mark propeller shaft and axle yoke, or companion flange, for alignment reference.
  3. Disconnect and remove propeller shaft.
  4. Remove old seal with a generic seal remover (1)(Figure 1) from overdrive extension housing.
Oil Pump Seal - Installation4 steps
△ CAUTION
If the torque converter is being replaced, apply a light coating of grease to the crankshaft pilot hole. Also inspect the engine drive plate for cracks. If any cracks are found replace the drive plate. Do not attempt to repair a cracked drive plate. Always use new torque converter to drive plate bolts.
  1. Clean and inspect oil pump seal seat. Then install seal using Seal Installer C-4193A.
  2. Clean and inspect torque converter hub. If nicks, scratches or hub wear are found, torque converter replacement will be required.
  3. Apply a light film of transmission oil to the torque converter hub and oil seal lips. Then install torque converter into transmission. Be sure that the hub lugs mesh with the front pump lugs when installing.
  4. Reinstall the transmission into the vehicle.Installation
Oil Pump Seal - Removal3 steps
  1. Remove the transmission from the vehicle Removal.
  2. Remove the torque converter from the transmission bellhousing.
  3. Use a screw mounted in a slide hammer to remove oil pump seal.
Factory service manual
From the 2008 KK factory manual — descriptions, specs, torque & procedures for this part.
SEAL SPROCKET📷 1
23 - REAR 41 - SNAP 5 - TABBED THRUST WASHER
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SEAL SPROCKET📷 1
23 - REAR 41 - SNAP 5 - TABBED THRUST WASHER
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SEAL SPROCKET
23 - REAR 41 - SNAP 5 - TABBED THRUST WASHER
FRONT OUTPUT SHAFT SEAL
The front output shaft seal and wear sleeve cannot be serviced in the vehicle. The transfer case must be disassembled to remove the front output shaft assembly and seal.
SEAL - INPUT SHAFT

Removal

1
Remove the transfer case from the vehicle. See REMOVAL.
2
Remove the input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.

Installation

NOTE: Lubricate all seals with MOPAR® ATF+4 prior to installation.
1 - HANDLE C-4171 2 - INSTALLER 9672
1
Install the new input shaft seal with Installer 9672 and Handle C-4171.
2
Install the transfer case into the vehicle. See REMOVAL.
3
Check the transfer case fluid. See STANDARD PROCEDURE.
SEAL-REAR OUTPUT SHAFT📷 9

Removal

1 - HOLDER C-3281 2 - REAR COMPANION FLANGE
1
Remove the rear propeller shaft. Refer to REMOVAL .
2
Using Holder C-3281 (1), remove the rear companion flange (2) nut.
3
Remove the rear output shaft flange from the output shaft. If necessary, use a suitable 2 or 3 jaw puller to
remove the output shaft flange. 1 - DAMPER 2 - BOLTS
4
Remove the damper bolts (2) and damper (1), (if equipped).
5
Remove the rear output shaft seal with a suitable pry tool or a screw mounted in a slide hammer.
1 - REAR HOUSING 2 - REAR COVER 3 - REAR COVER BOLTS
6
Remove the rear cover bolts (3) and the rear cover (2), from the rear transfer case housing (1).

Installation

NOTE: Lubricate all seals with MOPAR® ATF+4 prior to installation.
1 - HANDLE C-4171 2 - INSTALLER C-4210 3 - REAR OUTPUT SHAFT SEAL
1
Install a new rear output shaft seal (3) into the rear cover with Installer C-4210 (2) and handle C-4171 (1).
1 - REAR HOUSING 2 - SEALANT
2
Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of rear housing as shown in
graphic (2). Keep sealer bead width to maximum of 3 mm (1/8 inch). Do not use excessive amount of sealer as excess could be displaced into the oil pump. 1 - REAR HOUSING 2 - REAR COVER 3 - REAR COVER BOLTS
3
Install the bolts (3) holding the rear cover (2) onto the rear housing (1). Tighten the bolts at the dowel
locations first, then the remainder of the bolts in a crisscross pattern. Tighten the bolts to 27 N.m (20 ft. lbs.). 1 - DAMPER 2 - BOLTS
4
Install the damper (1), (if equipped), and damper bolts (2) into the case. Tighten the damper bolts to 27
N.m (20 ft. lbs.). 1 - HOLDER C-3281 2 - REAR COMPANION FLANGE
5
Install the rear output shaft flange onto the output shaft.
6
Using Holder C-3281 (1), install the rear companion flange (2) nut. Tighten the bolts to 122-176 N.m (90-
130 ft. lbs.).
7
Install the rear propeller shaft. Refer to INSTALLATION .
8
Check the transfer case fluid level. See STANDARD PROCEDURE. Correct as necessary.
SENSOR-MODE
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SHAFT SEAL
60 - FRONT 36 - REAR OUTPUT 12 - SHIFT FORK PADS
SHAFT SEAL
66 - FRONT 42 - WORM OUTPUT 18 - SHIFT RAIL SNAP RING
SHAFT SEAL
60 - FRONT 36 - REAR OUTPUT 12 - SHIFT FORK PADS
SHAFT SEAL
66 - FRONT 42 - WORM OUTPUT 18 - SHIFT RAIL SNAP RING
SHAFT SEAL
60 - FRONT 36 - REAR OUTPUT 12 - SHIFT FORK PADS
SHAFT SEAL📷 1
66 - FRONT 42 - WORM OUTPUT 18 - SHIFT RAIL SNAP RING
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SEAL-FRONT INPUT SHAFT-MP3022📷 1

Removal

1
Remove the transfer case from the vehicle. See REMOVAL.
2
Remove the front input shaft seal with a suitable pry tool or a screw mounted in a slide hammer.

Installation

NOTE: Lubricate all seals with MOPAR® ATF+4 prior to installation.
1 - HANDLE C-4171 2 - INSTALLER 9672
1
Using Driver handle C-4171 (1) and seal Installer 9672 (2) install the front input shaft seal.
2
Install the transfer case into the vehicle. See INSTALLATION.
3
Check the transfer case fluid. See STANDARD PROCEDURE. Correct as necessary.
SEAL-FRONT OUTPUT SHAFT
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FRONT OUTPUT SHAFT SEAL📷 1
The front output shaft seal and wear sleeve cannot be serviced in the vehicle. The transfer case must be disassembled to remove the front output shaft assembly and seal.
SEAL-REAR OUTPUT SHAFT
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