My 2004 Rado sprung a BIG leak at the front transfer case output shaft seal (leaking like a stuck pig). I do not have the seal press kit required to install the front seal properly (delicate double-seal). Has anyone figured out a novel new way to install this seal PROPERLY using an alternative to the fancy GM spec seal-install-tool? Also wondering what the best tool/method is for removing the old seal without damaging the housing. Thank you.

 

See if you can possibly rent the tool. Barring that wood and a hooked J-bar should get it out. Spray it with penetrating oil for 12 hours.You can use several methods to reinstall the new seal. Might as well change the TC case lubricant.as well after you are done. You can flush the rest of the possible "stuff" with cheap oil and let it drain out real good before installation of the new fluid..

I HIGHLY suggest synthetic lubricants, since some of the seal may well have gotten in there and you don't need that at all, as well as synthetics are better then non-synthetics. I used to sell both, many years ago, so I know all about lubricants.