I'm not sure what you mean by the seal is tapered. The OD of the seal should be the same diameter from front to back. The flat side of the seal goes toward the outside and the open side with the rubber lip goes toward the inside of the transfer case. Please show a photo of the wear area on the yoke because that is where the seal rides and if it is worn with a groove in it the seal will still leak. If the yoke has a groove worn in it you will have to use a speedie sleeve on it or replace the yoke. If the rear output yoke is leaking it's a good bet the front drive yoke is leaking too.

The yoke looks OK (I think). The seal is the type that does not have an open side. I'm pretty sure the side shown in pic #2 goes towards the TC, right?

The Papas goes into the mamas and it should do it freely and easy.
I used this rules for any oil seal that I need to replace. On TC, diff, crankshaft....

So the Yoke is easier to enter in your picture #1 since it don't go against the rubber lip.

I appreciate the answers. I still question myself on what often seems obvious. It's much easier to ask for clarification online when bored at work than it is to blow an entire sunny weekend redoing something that's wrong 

And thanks to Pascal's colorful explanation I'll never forget it.

I'm really battling with this output seal. I can't get it to seat in any further than what is pictured. I already destroyed one new seal from banging on it. I'm using a 2" socket and a hammer. The TC bore feels smooth. Is it supposed to go in any further than this or just to that "lip" that's visible in the photo from my first post above? Seems like it needs to go in further in order for the yoke to fit on properly.

Quebec Jeep wrote on 08/24/13 at 17:27:41:


Yes, I almost religiously take "before" pics prior to every project - I have thousands. But, of course, I neglected to do so here.

I started with a PVC pipe and it broke. I moved up to a socket and 3lb hammer and it still won't budge any further. In fact, the first seal bent inward and the second one is starting to do the same.

I also tried putting the yoke on and screwing it down in hopes of pushing in the seal. In the process I destroyed both the seal and the flange on the yoke. The flange bent backwards without moving the seal. Now I will be ordering a new yoke.

Something just doesn't seem right. I'm thinking the seal is going as far as that lip on the inner bore of the TC and stopping. Does anyone else know if their TC has that same lip?

I've been to 5 parts stores today plus scouring the web trying to see if maybe I have the wrong seal. Everything I'm reading and hearing says I have the right one but it just won't seat.


EDIT:
I just found this pic from last year. I redid the e-brake but I did not replace the seal on my initial rebuild. It should have looked the same a couple days ago as it does in this old pic. The seal definitely slides back further but it appears to be a different type of seal. It does not have a flat face like my new ones. Unfortunately, the one pictured here is has been reduced to a pile of metal crumbs.

From the looks of the picture I would say that part of the old seal is still there. It does not look like a machined "lip".