Join Date: Dec 2000
Location: Port Angeles, Washington, USA
Brad, I just replaced mine and it's a piece of cake. Here is what I recommend.
1. Get a new seal and bushing kit from your local parts store $7.99 and a 2 ¼” flat washer.
2. Remove your driveline and the 4 bolts securing your Trans nose cone and the Speedo cable and Speedo driven gear.
3. Remove the nose cone, if its stuck whack it lightly with a soft mallet or the wood handle of a hammer.
4. Do a ruff clean of the nose cone in solvent and remove the old seal then the bushing by using a punch to crinkle it inward so as to collapse it and grab it with a pair of needle nose pliers.
5. Do a final through cleaning of the nose cone & dry it off completely. Then get some Vaseline and the 2 1/4" flat washer, now you are ready to install the bushing, coat the bushing and bushing bore of the nose cone with Vaseline (Don't use Grease) place the nose cone rear end up and place the bushing squarely into position place the 2 1/4" flat washer on the bushing and use a large socket on the washer and start driving the bushing by hitting the socket with a hammer, start slow and easy until you verify that the bushing has entered the nose cone squarely, after you confirm it's going in square, drive it home. It should be 0.0010 below the bore.
6. Very “Lightly” coat the outside of the new seal with RTV silicone and drive it into the nose cone with a 2x4 laid flat and a hammer.
7. Clean the trans mating surface and make sure the large round O-Ring is in position correctly, then lubricate the new seal in the nose cone with Vaseline place a small bead of RTV silicone on the nose cone to trans flange and install with a light blow of the mallet if needed. Reinstall the Speedo driven gear & cable and apply a thin film of Vaseline to the driveline slip yoke and install the driveline. You’re done.
Installing the new bushing will cut down on some vibration and help the seal to last longer.