Transfer Case Tailshaft Seal Leak
 

The transfer case tailshaft seal started leaking on my ’99 at 150k. I replaced the seal and driveshaft yoke, but it still leaked. It wasn’t too bad, so I let it go. I have 310k on it now and it’s leaking pretty good so I figure it’s time to take care of it. I’m thinking the tailshaft bushing needs to be replaced. The GM manual covers the seal replacement, but not the bushing. Is it an easy job? The bushing is only $10, but the tailshaft housing is $500, so I’d really like to replace just the bushing and not damage the housing. What’s involved? Interference fit bushing? Heat the housing with a hot air gun and cool the bushing in the freezer? I’ve got a pretty good selection of seal and bushing drivers. Any other special tools required? Thanks!

Re: Transfer Case Tailshaft Seal Leak
 

HELP! I think I’m in over my head on this one. I decided to try to pull the tailshaft housing off the rear of my transfer case to replace the bushing. It’s a New Process 246 GM in my ’99 5.3 with the auto 4x4. I got the housing loose and pulled it off about a half inch, but a whole lot of other stuff wants to come with it that I was not expecting! I thought it would just slide off the tailshaft, but the tailshaft and other stuff wants to come with it. I’m doing this with it still in the truck BTW. What should I do now? Can anyone help???? Thanks!

Re: Transfer Case Tailshaft Seal Leak
 

Never mind. I finally got it. I'm a little slow, but I figured it out.

Re: Transfer Case Tailshaft Seal Leak
 

Did you get the bushing in?

Re: Transfer Case Tailshaft Seal Leak
 

Yeah I got it. Had to take the TC out and do it on the bech the right way. I was trying to do it without unbolting it from the trans. Dumb idea cuz it's a lot of work to remove the torsion bars and x-member. Like I said, I'm a little slow. Thanks anyway!