Update on this: I removed the drive shaft, then the yoke nut. It is 30 mm and it does require you to have a thinner wall socket than a normal 30 mm impact socket. I went to O'Reillys, and they have a good loaner tool program. They had a deep well 30 mm socket which fit perfectly. I used an M18 Milwaukee impact (borrowed) and the nut came off easily. Then you have to following dis-assembly sequence (just a few details that will help the first-timer like myself):
1 After the flange nut is removed, then make a mark on the flange and the transfer case housing-for alignment , remove the flange, then a flat washer and rubber washer from the spindle coming from the rear of the transfer case.
2. Then you have an oil seal that surrounds the spindle to remove in order for the old driven gear to get pushed out. Carefully, using a flat screwdriver, tap the outside diameter away from the outside hole circumference of the transfer case and it comes off easily, just like an oil seal on your brake rotors. Don't damage it or you may have to replace it !
3. Remove the 11mm bolt that secures the small bracket that holds the speedometer gear into the transfer case as is mentioned above. Then just push out the driven gear thru the rear of the transfer case - which looks just like the picture on the first page. Then install the new driven gear thru the rear of the transfer case.
4. Then carefully re-install the oil seal with a wooden block to seal around the rear hole of the transfer case - install the flange (make sure you align the marks you made above), then the rubber washer, flat washer and then install the nut and torque to spec (as mentioned above by others).
5. Then pick up the front end of your rear drive shaft and install the bolts.
- By the way, the driven gear I ordered from the link on the first page came in two days and cost $35 plus $8 shipping. People at the transmission place were very helpful and knowledgeable.
I found that my speed fluctuation decreased, but the speed is now reading 3 MPH high - it was reading 5-6 MPH too high -so I may replace the speedometer gear going into the front of the transfer case. The plastic end of the old one looked good-I had replaced it just a few years ago. So there you have it. If I left out any details, please update. It wasn't that difficult to do. Hope this helps.
