I'll throw this up here in hopes that those who've never done this type of repair may find it a little less intimidating. I developed a steady leak at the back of my AX5. It was 10w30 oil, which I run in my transmission. I cleaned up all the grime, trees and dead fish jammed in there and tracked it down to a weep hole at the bottom rear of the flange the Transfer case bolts to, passenger side.
Here 's the weep hole, just below the TC bolt.
I talked with Mean Max and he had several good pics of the AX5 but none showed this hole. There shouldn't be any oil in this part of the transmission, the seal is made up at the output shaft. I figured the seal had let go and the job would be to pull the Transfer case and replace the seal.
Begin with the usual, PB Blaster on the 6 (9/16") transfer Case mounting nuts, block the tires, support the transmission, remove the transmission mounting bracket nuts ( 5/8" ), torque arm stud nut ( 9/16" ) and pull the skid plate (3/4" ). Place Transfer case in Neutral and unbolt the front driveshaft ( 8mm ) from the TC yoke. Wrap the Ujoint with tape to keep the caps in place and tie the DS to the frame rail, out of the way. Drain the Transmission (15/16ths ) and the Transfer Case ( 30mm ). Now mark the yoke orientation and unbolt the rear driveshaft ( 8mm ). Tape Ujoint and slide it out of the Transfer case tail cone and set it aside.
On the driver side of transfer case, disconnect the Range Lever Shift Rod by prying it out of the rubber bushing, gently pry off the vacuum harness and disconnect the vent hose.
At the rear of the TC, disconnect the speedo plug and tie it up out of the way.
Lower the support jack a bit to access the top two TC mounting nuts. Don't put too much stress on the exhaust pipe going under the oil pan.
Your choice of tools now to remove the mounting nuts, it's very tight in there. I used a 4" x 9/16" open end wrench on some, 9/16" box on some and 9/16" flare wrench on others. A couple of them took 1.3 million turns each, an 1/8" at a time....
I put a floor jack under the TC for support and with all the nuts off, slid the TC to the rear and out. Probably didn't need the floor jack but I liked the insurance.
Here's the jacking setup. The floor jack is actually behind the Transmission, not under it.
Rear of the AX5 cleaned up. Weep hole is at the bottom of lower center cutout. None of Mean Max's AX5 pics had this hole. Maybe it's a late '95 thing. Camera angle makes output shaft look off center.
Here are the seals. The Transfer Case input seal, on the right, was in perfect shape so I elected not to change it. I'm doing a SYE conversion soon, with TC in place, and I'll change it then.
Use your seal puller of choice but it popped right out.
i used a VERY light coat of RTV on the seal race but it's not required according to the FSM, and I pressed the seal in by hand, solid face toward rear. It sits about 1/8" behind the face of the housing when pushed back tight. Prime the inside face of the seal with 10W30 oil.
While I had the TC out I gave it a quick face lift. Cleaned with Brake Cleaner, 2 coats of gray self-etching primer and 3 coats of Engine enamel. Should be easier to hose off the moose hair and Hummer debris now.
Here you can see the vent tube, vacuum fitting and range lever. Three of the studs turned out instead of the nuts coming off but I still had three studs to help locate the Case during reinstall.
From left to right, drain and fill plugs, speedo housing and Tail cone.
Transfer case back in place. I just benchpressed it up, balanced on one knee, and turned the shaft by hand til the splines lined up and slid it in. Install 6 nuts and torque to 26ftlbs. I don't know how you get a torque wrench on them, I just made em goodntight.
I changed out the driveshaft Ujoints just for fun (the yellow marking paint) but that writeup is already out there.
From the rear, ready to install the skid.
Well that's about it. Fill the transmission with 10w30, the Transfer case with ATF Dextron II, and connect the driveshafts @170in.lbs. Plug in the Speedo and Vacuum plug, attach the vent hose and press the shift arm rod back into the Range Lever. Torque the skid plate bolts to 30ftlbs, lower the jack and tighten the Transmission Mounting nuts and Torque Arm stud @26ftlbs. and go find something to climb.
Thanks for reading, I hope this helps someone out there.