2nd Gen Non-Engine/Transmission Transfer Case Still leaks

[McCRam]

I put new seals on the front output shaft of my transfer case yesterday. I only drove it from the garage to the drive way, but this morning it was leaking from the same spot again. From behind and in front of the flange. Very frustrating. I did get it tightened to 150 ft/lbs, and I didn't have any extra parts left over. Does anyone have any ideas as to what I might have done wrong? Better yet, how to fix it? I think I'll try putting on a sleeve, but that wont fix the leak from the nut side of the flange.

 

[Partyat33]

I can't offer any help, but I can tell you that several TDR members have had the same experience including me. Hopefully somebody has a solution.



Dennis

 

[JSykes]

I encountered a similar problem. Replaced the rear seal and gasket. Immediately leaked from the same spots. Throroughly PO'd me as I had to go through a bunch of crap to get it repaired.



Anyway, one thing you need to try is clean the vent tube on the transfer case. There are some wires and hoses that come from the top of the transfer case. The green tube is the vent tube. Follow it up from the Xfer case into the engine compartment on the drivers side. The vent tube terminates around the IAT sensor and Lift pump. Pull the end piece off the vent tube and blow it out using shop air. Re-install the clean vent tube.



These things clog up fairly easily and should help (or eliminate) your problem.



Good luck,



Jay

 

[McCRam]

I forgot about the vent tube, I will clean that out next time I get under there. I'm going to spend more time cleaning all the parts. If I doubled up the flange seal, ( nut side ) would that be bad? I figure It might mess up the torque readings, but the book says to tighten between 130 - 150 lbs so it shouldnt be that bad. Or maybe some silicone? I'll try that last. I hope that a sleeve and another new seal should fix the case seal. I had good luck on a rear shaft once putting silicone on the lip of the seal. It was leaking between the seal and the case. I'm going at this again on thursday, I'll let you now how it works. I hope I have better luck with the rear axle seal.

 

[nfox]

Leaking Transfere Case

Make sure before when you put a speedy sleeve on the yoke that you put some sealer inside of the speedy sleeve before you press it on the yoke. You should also have a rubber washer seal that is shaped the same as your front output shaft splines which should compress when the nut is tightened down on the yoke, sometimes this seal is forgotten and it will leak around the shaft seal and not the yoke seal.

 

[TomGolden]

Last summer I noticed my Xfer case leaking, and it looked like the rear seal. I replaced it, and now I get no more leakage from the seal, but I still get fluid sprayed all underneath the bottom of the cab.



I also removed the end of the vent tube and cleaned it, that made no difference. I periodically remove the rubber plug on the top of the rear output yoke of the Xfer case and clean it, reseat it. That seems to stop the leaks for a couple weeks, but they always start up again.



Tom