Transfer case seal replacement

[Archive]

I was wondering if any of you that have replaced the output shaft seals on your transfer cases have any suggestions for me as it looks like I am going to have to replace my front output shaft seal as it is starting to leak pretty good. I have replaced others on differant vehichles but was just wondering about any tips you all have come up with.

Thanks,
Paul

------------------
'96 2500 ext. cab, LB, 4x4, 5 speed, 3. 54, TST 280 cam plate, AFC spring kit ,pyro and boost gauges mounted on A-Pillar, tinted windows, 16x8 Eagle alloys series 1219, 285/75R16 Durango A/T's

 

[Archive]

Flatlander,

I went to replace my rear output shaft seal and after removing the old one, realized the local dealer had sold me the wrong sized one. When I popped the old one out, I just caught the edge with a screwdriver and tapped it out. Good thing as I was able to reuse it until I got the correct one. One thing to be careful of. The seal held enough oil to splatter in my face!

 

[Archive]

Hi Flatlander-I just noticed the other day that the front shaft seal on my xfer case is also leaking. Mine is also a 96. When you change it let us all know how much of a pain it was and how much stuff you had to take off. Mine has 60500 miles. I wonder if it started leaking cause it doesn't rotate near as much as the back one? dm

------------------
1996 2500, 4x4, 5-speed, 3. 54, Full Amsoil with bypass filtration,
So Far Almost Totally Stock!

 

[Archive]

Just when throu this on my newly acquired '96 4x4. I thought it was a seal, ordered seal, rubber washer, and new nut. It is recommended not to reuse the old one.

Started tearing down and discovered the rubber washer behind the nut was installed wrong from the get-go. Was rolled and deformed on installation. Took a chance and put new rubber washer in and it has not leaked since. Has lasted about a month, so far, so good.

I have a seal, nut and rubber washer extra, if you are interested. Chech the leak source carefully. If the oil is coming out the joint side of the flange and not the seal, you may have the same problem I had.

Good luck... ... . John

------------------
'94 2500 Diesel Reg. Cab
Auto 3. 54 4X4 TST 230hp
"If you can't Dodge it, Ram it!
'96 2500 diesel clubcab 4x4 5speed

 

[Archive]

It's Deja Vue all over again!

The front seal on my 96 4x4 started leaking saturday. It has 73K miles on it.

------------------
Gregor Switca
-------------
96 2500 4x4 auto SLT.
Torque is a beautiful thing

 

[Archive]

I have replaced this seal on my 96 and it's a pretty straight forward repair. The hardest part was finding a suitable tool to drive the seal in. I had a 4" piece of 2. 75" OD bronze pipe laying around that did the trick. You need something smaller than 2. 75 and close to the diameter of the metal seal surface but it has to be hollow enough to allow for the output shaft. (there is a special Miller tool #6888for this). The FSM is very specific that the seal be seated between 0. 080-0. 100 below the edge of the bore. The only other trouble I had was generating the required torque for the nut in the confined space under the truck.

Bob

 

[Archive]

I got the seal and rubber washer today but they did not have the nut it appears to be back ordered from Dodge. My question is what size socket do you need for the nut on the transfer case front yoke, it is always nice to know before you crawl under the truck and get everything apart and then find out you don't have the right size socket plus it gives you a good reason to add to your tool inventory #ad


Thanks,
Paul

 

[Archive]

The nut is an inch and 1/8th. Good luck!

John

 

[Archive]

I had the seal begin to leak at 40K miles. At the time I was running Rotella T 15-40 in the case. You can do this. I looked up at the leak and figured before doing the seal job, I would try something else. I drained the case and pumped in some gear oil and I now have 71K on the truck and still haven't touched the seal.

Chris @ autowurks diesel

------------------
520 Rear Wheel H. P. and 800+ ft/lbs Torque = 15. 5 sec @ 97 mph with the rear wheels spinning in 5th gear going through the traps in the quarter mile. No slicks here, pal, no fancy auto transmission, just the truck in full street trim, 7400 lbs. of Auto Wurks Diesel/BD Performance raging, fire-breathing DIESEL POWER

 

[Archive]

One more question, how have you kept the transfer case output yokes from turning while taken off and putting on the nut. Just leave it in gear or hold the yoke with something and if so what?

Thanks again for all the help,
Paul

 

[Archive]

I just put the thing in gear. Had no problem.

John

 

[Archive]

Thanks Big John and the others for replying I will tackle this in a few days. I am wondering if it might not just be the rubber washer seal under the yolk and not the seal as it looks like it is leaking from around the companion flange and not from behind the dust shield on the yoke. We will soon find out #ad
.

Paul

 

[Archive]

Thanks guys, mine has 148,000 miles on it, front and back are leaking, any information will help. I have 3/4 drive set, that should help. How do you get to the rear seal, pull the tail off????

------------------
96 CC 4X4 2500 SLT PrimeLoc, GUTTED CAT, Lots of Ham Radio gear, NO IGNITION NOISE!!! Love my diesel!!!