Engine/Transmission (1998.5 - 2002) Rear xcase seal dead in 1k miles

[ROADWARRIOR]

I'll try to keep this short. I ordered this truck and lost the rear xcase seal under warranty. The replacement leaked within weeks and was replaced again. That seal lasted up until last month at which time I had a reputable dealer install the new heavy duty version seal. I see it is leaking again today with only a thousand miles on it. What should I look for? The tech said the yoke seal surface was great and when I checked the carrier bearing, I could only move it about a quarter inch max. Could a . 5 quart overfill cause this? I overfilled the xcase by . 5 quart shortly prior to the first of the last two seals failing.



Any ideas?



Thanks,

Dan

 

[Tiger Rag]

Man, that is an expensive seal to be leaking although I understand from a diesel shop that they frequently leak after a new one is installed. I just replaced mine after the carrier bearing failed and took the transfer seal with it. Mine is not leaking but I haven't overfilled my transfer case seal either. I did take light, light grained sand paper and gave it a light hit to check for burrs, etc.

 

[jkern]

mine too

just noticed mine is starting to leak too. truck has 60k miles on it. i replaced the xcase oil with amsoil synthetic about 20k miles ago. i wonder if there is something in the oil that is not compatable with the seal?



how hard is the seal to change? can i do it with the xcase in the truck? i guess that is the big question.

 

[Tiger Rag]

just noticed mine is starting to leak too. truck has 60k miles on it. i replaced the xcase oil with amsoil synthetic about 20k miles ago. i wonder if there is something in the oil that is not compatable with the seal?



how hard is the seal to change? can i do it with the xcase in the truck? i guess that is the big question.

Yes, but you have to pull the driveshaft. No big deal though. Pretty easy.

 

[2-ND TIME]

xcase seal

Is there a vent on the xcase and is it plugged? Sorry the shaft movement, that was longituduality and how about side play ( is there a bearing going ask he dollarshop this one) what in thousands " might it be??? Is there a noncompadability with the oil that you might be using? Is the surface of the seal rough and it is wearing the seal?

 

[Supermod56]

drain the 1/2 quart out and check the vent. Also if there is a bushing in there (can't remember) and it has play in it that will do it also.



Tom

 

[ROADWARRIOR]

Shouldn't the weep/drain hole in the outer rubber cover of the seal be on the bottom? I looked at the seal and found the weep hole is at the 3 o'clock position and there is water inside the rubber seal mixing with the oil coming out making a nice pink foam. I pulled the fill plug and there is no water in there. The dealer said to bring it in Wed. and they would take a look at it. On the seal there is a indicator block exactly 180 degrees opposite of the drain/weep hole. I would think this should be at the 12 o'clock position and the drain hole at the 6 o'clock position.



Dan

 

[klaybus]

I would think this should be at the 12 o'clock position and the drain hole at the 6 o'clock position.



Dan

Yep, thats correct. The weep hole should be at the bottom. I too need to replace mine! I have to add about a 1\2 qt. every 6 months. It's creating quite a mess on the underside of my truck. Been leaking for about a year.



Clay

 

[NoSeeUm]

I noticed that I had some fluid collecting around the rear seal when I did my fuel system. I looked yesterday and no fluid, keeping an eye on it. I have 46k on my truck.



Jim

 

[klaybus]

Thats the bizarre part for me. No fluid at all on the rear seal! But I've got fluid all over the underside of my truck at the rear of the transfer case. I'm assuming it's got to be the seal.....



Clay