Output shaft seal leak (second time around)

[cowboysgottacummins]

THis past winter I had the u-joints replaced in my drive shaft. After which I noticed a leak at the output shaft on the transfer case. I assumed that the bad u-joints had ruined the seal and it probly should have been replaced with the u-joints. So I got it done at a local shop in late Feb after an oil change revealed the transfer case was nearing empty



Can't say for sure if it ever stopped leaking after it was fixed, there was so much fluid under the truck and the shop didn't clean it off when they changed it. I honestly didn't give it another thought until I noticed I left a few spots on my customer's driveway a few weeks after it was fixed



Sure enough it is leaking again. Called the shop and they asked me to bring it back in, which I will soon. But curious here if we should be looking at another issue, could the carrier bearing or an out of balance drive shaft be causing this? I don't feel any significant shutter or vibration (like I did when the ujoints were bad) truck drives fine, but is spitting out about 2 qts of fluid over 3-4,000 miles so its definitely a problem. Hesitate to just stick another seal in it if there is something else going on here. The leak is definately coming from the back side of the transfer case. and appears to be slung off the u-joint. covering everything in its path.



You advice is appreciated.

 

[cerberusiam]

Bushing in the extension is probably worn and that is causing seal to leak. Bad ujoints, bad carrier bearing, or just miles will cause the t-case output bushing to wear.

 

[Gibbs]

Completely agree with Cerb. I just replaced the rear output on my t-case at 144,000 miles. I had to replace the rear output on my buddy's '06 with only 100K miles on it. The rear output "cone" isn't expensive. I got it from Dallas Dodge (Texas) for about $90. Ask for Brian Condley and tell him Will from Georgia sent you. (214) 319-1237 is his direct line. I have no financial interest in them, but Brian has treated me right and it's wholesale prices.

 

[HOBrian]

Good info Will!! Thanks!!

 

[cowboysgottacummins]

Thanks for the info will head that direction.

 

[PLohr]

Can the extension housing be removed without pulling the entire transmission to change the output shaft bushing?