Here's a general outline. Specific steps and tools may vary slightly depending on the exact transfer case model in your Tahoe (NP241, NP261, etc.). Always consult a repair manual specific to your vehicle's year and transfer case type. A Haynes or Chilton manual would be a good investment.
Tools You'll Likely Need:
* Transfer case repair manual: Absolutely essential.
* Socket set and wrenches: Various sizes, including metric and possibly SAE.
* Transmission jack or suitable support: To safely support the transfer case.
* Pry bar (or seal puller): To help remove the old seal.
* New rear output shaft seal: Get the correct part number for your transfer case.
* Penetrating oil (like PB Blaster): To help loosen any stubborn bolts.
* Clean rags or shop towels: To keep everything clean.
* Torque wrench: Essential for tightening bolts to the correct specifications.
* Impact wrench (optional but helpful): Can make removing and installing bolts much easier.
General Steps (Consult your manual for precise instructions):
1. Disconnect the battery: This is a crucial safety precaution.
2. Support the transfer case: Use a transmission jack to support the transfer case. This will prevent damage and make working easier. You may need to partially or fully remove the driveshaft to get access.
3. Drain the transfer case fluid: This is crucial to avoid making a mess.
4. Remove the driveshaft: This may involve unbolting the yoke from the transfer case output shaft.
5. Remove the retainer (if applicable): Some transfer cases have a retaining clip or ring holding the seal in place.
6. Remove the old seal: This is often the trickiest part. A seal puller is the best tool, but a carefully used pry bar can work. Be extremely careful not to damage the output shaft. Work the pry bar or puller slowly and evenly.
7. Clean the output shaft: Thoroughly clean the shaft where the new seal will sit. Any debris will damage the new seal.
8. Install the new seal: Generally, the new seal is pressed in using a socket that's the same size as the seal's outer diameter. Tap it in evenly and carefully to avoid damaging it. Don't hammer it in too hard.
9. Reassemble: Carefully reassemble the transfer case, paying close attention to the order and torque specifications found in your repair manual. This includes reinstalling the driveshaft, refilling with the correct type and amount of transfer case fluid.
10. Reconnect the battery:
11. Test drive: After reassembly, test drive the vehicle to ensure there are no leaks.
Important Considerations:
* Transfer Case Variations: The specific procedure will vary depending on the transfer case model. Your repair manual will have the detailed instructions for your particular Tahoe.
* Safety: This repair involves working under your vehicle. Always use jack stands for safety.
* Torque Specifications: Use a torque wrench and your repair manual to ensure all bolts are tightened to the correct specifications.
Again, this is a simplified overview. Always refer to a repair manual specific to your 2005 Chevy Tahoe's transfer case. If you're unsure about any step, it's best to seek professional help. Improper repair can lead to serious damage and costly repairs.
