Output shaft seal leak. HELP!

JakeH05 · Jun 26, 2013

I have been chasing a very bad transfer case output shaft seal leak for a month or so now. first replaced the seal. it instantly started leaking again within a miles drive down the road. I could get a slight amount of up play out of the yoke at the case so me and a buddy removed the transfer case and replaced the bushing, bearing, seal, and also did the pump rub fix and all looks great. The yoke is tight now and has zero play at all. We also replaced both u-joints on the rear shaft. took it down the road and within a mile it is leaking again pretty good. I can feel a very very slight amount of shimmy going down the road but very faintly and it drives great. just leaks badly and is slinging everywhere. i have inspected the housing for cracks and the cap in the yoke is not leaking. I have read every post i can find on the forums pertaining to this problem. Only thing i have not replaced and last on the list is the yoke itself. It seems fine but i guess i am going to order one of those next too.

Any help or input would be very much appreciated.:help:neener

Big Angry · Jun 27, 2013

There is a bushing in inside the transfer case that the slip yoke slides into, most likely, it's wasted too. If it's been a real long time that it's been slinging fluid, I had an instance where the TC back half was actually oval shaped, and no longer round, resulting in the new seal not fitting properly. Replace the bushing and check out the case to see if it's oval shaped now. Also, check the yoke for small grooves being worn in it from wear, it may be allowing fluid to slip by as well.
After 6 years of fighting this, and about $5G's in TC's and parts, I finally wised up and took the 4" non tapered block out of the rear of my CCSB, put a 3" tapered block, and am having a longer driveshaft made so the slip yoke sits in the TC housing the same amount it did stock, it's the only thing that I haven't addressed. Merchant Auto has some nice diagrams of the T case, and you can see the parts I'm referring to.
Good luck.

JakeH05 · Jun 27, 2013

tcase

I replaced the bushing and bearing...

nmeyer414 said:
Off hand, how much fluid are you putting back in the case? The 2 qts that it calls for or are you filling it plumb full thru the sensor whole in the top of the case?

1 quart a week...going to fill plug

nmeyer414 · Jun 27, 2013

Off hand, how much fluid are you putting back in the case? The 2 qts that it calls for or are you filling it plumb full thru the sensor whole in the top of the case?

JakeH05 · Jun 28, 2013

It may be unrelated to the leak but i noticed it started leaking about the same time the vibration developed. has Brand spanking new tires and wheels and front end parts so that rules out all of that....or so you'd think....lol

Output shaft seal leak. HELP!

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