AW4 4x4 Output Seal Replacement How-To? - JeepForum.com
 
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post #1 of 3 Old 03-30-2012, 07:22 AM Thread Starter
BigGreenoh9
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AW4 4x4 Output Seal Replacement How-To?

I need to replace the rear output seal on my 4wd AW4 trans, and I've searched and can't find any write-ups on doing this, which leads me to believe that it's a) hard/near impossible to do it w/o dropping the trans or b) so easy a caveman can do it. I'm not afraid to drop the TC and tackle it with the trans still in the Jeep, but am hesitant about needing to drop the trans if need be. What am I getting myself into once I drop the TC?

I've seen some write ups for 2wd AW4's, and its easy, but they stress that 2wd and 4wd seal replacements are different. Also I've seen that there's a bearing in there that may need to be replaced or it will cause the seal to leak in no time...is that the same for 4wd AW4s?


Current: 1997 XJ Sport 4x4 - 4.0/AW4/231
Previous: 1987 YJ - 4.2/BA10/207; 2005 WK - 5.7/545RFE/245
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post #2 of 3 Old 03-31-2012, 04:05 AM
CJ7-Tim
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The Factory Service Manual is your best resource for disassembly/assembly instructions and torque specifications.

To replace the rear AW-4 output seal on a 4x4 XJ you will need to remove the Transfer Case. The seal can be replaced while the AW-4 is in the Jeep. You carefully pry out the old seal and tap in a new one. Use a small amount of RTV Silicone in the seal recess. IDK what bearing you are referring to ?

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post #3 of 3 Old 03-31-2012, 09:19 AM Thread Starter
BigGreenoh9
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Sorry for the confusion on the bearing/bushing...once I was able to see the AW4 manual on Pirate4x4 at home (can't access it at work) I was able to see the bushing is for the tailcone on the 2wd transmission....4wd's don't have them

Thanks...sounds like an easy fix from what you described and what I see in the AW4 manual

Current: 1997 XJ Sport 4x4 - 4.0/AW4/231
Previous: 1987 YJ - 4.2/BA10/207; 2005 WK - 5.7/545RFE/245
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