Engine/Transmission (1998.5 - 2002) Transfer Case REAR Seal will not stop leaking!

[hammersley]

This is a rebuilt (totally) unit and I have had it several years and it develooped a rear seal leak. OK, we've replaced it 3-4 times - it still leaks... . NOW we have only replaced the seal located at the end of the Rear Extension Housing... ... looks like we have to go deeper... ... . suggestions... .

 

[Ol'TrailDog]

I can't help, but I can commiserate. When I saw the torque specs for the nuts on the rear pumpkin and output shaft I decided not to DIY and to take my truck to Mike's Off Road and have both the rear pumpkin drive shaft seal and the transfer case output shaft seal done for $100. The young mechanic almost gave up on trying to get the Knuts off, so I was glad that I didn't try.



Unfortunately, it wasn't many miles until the transfer output shaft seal started leaking again. The rear is still doing fine.

 

[mwilson]

I have been through this with the '94 that I had. There is a bushing/machined area in the transfer case extension housing that supports and steadies the yoke. That wears and lets the yoke flop more than the seal can take. I replaced the extension housing and then the seal would hold. They used to cost about 75. 00 or so, but that was a while ago. If you decide to try replacing it, get the numbers off of the extension housing and give it to the parts guys as there were a couple of choices.



Also, don't forget to check the transfer case vent. That can plug and let the pressure build.

 

[Stanbery]

I had that same problem with my truck, turns out there were 2 different deals, and the one they kept giving me was wrong. Finally went to a different trans shop and got the right one. What p/n is the seal you have? I'll list the number I got when I get back to the shop tomorrow.

 

[Stanbery]

Try seal p/n 05086054AA from your local Mopar dealer.

 

[SMorneau]

Quad 4x4 has the bushings for the transfer case extension housing and a hooded seal like the original. Hope that helps.

 

[hammersley]

where is Quad 4x4

Quad 4x4 has the bushings for the transfer case extension housing and a hooded seal like the original. Hope that helps.

where are these folks ?

 

[SMorneau]

quad4x4.com will get you there.

 

[Sticks]

I'd be taking a close look at the yoke as well. If it is grooved, it will leak no matter how many parts you throw at it.

 

[Curious Dave]

Check the outout shaft and make sure you didn't bend it somehow. Some people get crazy while wheeling and literally twist the output slightly causing it to bend. It can be a long shot. . but it does happen.

 

[FParisi]

My '95 had a leak, had the output seal changed twice before my mechanic replaced the speedo sensor. It is close to the very back of the transmission. That's what was leaking. Nice + dry after that .

 

[JMcCoy]

X2 on the yoke. Drag an emery cloth accross the yoke until it shines. I also used locktite in the outside if the seal, where it contacts the transfer case. No leaks. Good luck.

 

[SSolderitch]

are you sprayong fluid up on the floor pan? I changed out my seal, still had the problem until I noticed the cap in the center of the yoke was leaking. I TIG welded up the seam, however the cooling of cast (in sand) opened up 1/4" long crack. It was already installed. So I used pc-7 epoxy. fixed. I ALSO FOUND THE T-CASE VENT BREATHER CLOGED. It is cocated behind the valve cover. Found one that fit at NAPA for $3.