Transfer Case Seal Replacement - 1995 3000GT VR-4

These instructions apply to a 1995 Mitsubishi 3000GT VR-4, but are easily transferable to any year of AWD 3000GT or Dodge Stealth.



Updated December 9th 2002:
Please note that there has been an official recall on the transfer case seals for all years of AWD Mitsubishi 3000GTs and Dodge Sealths. If you have FWD car, this does not apply to you as you do not have a transfer case. The Recall Number is : 02V143001
The NHTSA website has more info on this recall, and you can click here to go to this specific recall.






The Transfer Case

    The above are pictures of a transfer case from a 1995 3000GT VR-4 (second-generation, 6-speed transaxle). The purpose of the transfer case is to take the torque transmitted by the center differential (inside the transaxle housing) through the transaxle output shaft and rotate that motion 90 degrees so that the rear driveshaft is turned. Thus 50% or more of the engine's torque is transmitted through the shafts and gears in this casing.
    Further, if the transfer case were to run dry (no oil), the gears, shafts, and bearings inside would rapidly get very hot and damage would occur. In the extreme case, the bearings may cease to function and the transfer case shafts could lock up (stop spinning). This would cause all 4 wheels of the car to stop rotating, sending the car into an uncontrollable skid. As you can imagine, this a little bit of a safety hazard.
    In 2002, Mitsubishi officially recognized that some transfer cases on 3000GTs leaked oil from the seals and could eventually run dry; thus there is an outstanding recall on these seals. If you notice any oil on the outside of your transfer case, please at least check the oil level in your transfer case. If you suspect that oil is leaking from your transfer case seals or you notice a puddle of gear oil under your transfer case, Do Not drive the car until you resolve the problem.


The Procedure

Transfer Case, As Removed
 

 
Closeup of Female Input Shaft Connection
 
  Note the caked-on dirt and clutch dust on the seal around the shaft. That's probably an indication of a leaking seal, but the leak doesn't look that bad.

 
Output Shaft Seal and Housing
 
  Not too much dirt buildup here. Splines look good.

 
Remove Old Seals and Install New Seals
 
Picture is with the new input shaft seal installed. You can remove the old one by carefully prying it out with a screwdriver. The new seal is pressed in with a "Special Tool" or can be carefully done by hand. The official Mitsubishi tool is MD998304 "Oil Seal Installer". For the output shaft seal, it can also be removed with a screwdriver or pick. The tools needed to install it properly are MD998812 "Oil Seal Installer Cap" and MD998824 "Oil Seal Installer Adapter". I opted to take my transfer case to my local dealer and have them install the new seals with the "Special Tool" for a few bucks, just so that I would know that the new seals were seated properly.

  •  
    New Output Shaft Seal
     
      Same drill as the input shaft seal.

     
    Cleaned Up with all 5 Bolts Present
     

     

     






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    Last Modified Wed Dec 29 2004 18:31:48 Pacific Standard Time