D2 Rear transfer output oil leak

[ibest]

Help ! Friend has 2005 D2 auto,low k's onroad use. Rear transfer seal replaced as leaking. He is a thorough & competant home mechanic. Still leaked . Several seals later,having checked the surface ( smooth as & no groove ) & checked for taper on the flange, found no runout in the shaft,no out of round on the flange & no cracks in the case,still leaks. Breathers are good. Latest seal fitted & vehicle sat 3 days, no leak. Moved in his yard a few meters shifting trailer,!st & reverse only,maybe 5 kph & perhaps 40 meters in all. Dumped a puddle,took 400 ml to fill. Oil is apeearing inside handbrake drum,not coming along splines,they are dry at nut end. Seal is lubed when fitted & a tool was made to push it in square. One of these seals was eased over flange & then flange fitted,then eased back, spacers positioned & eased back in to correct depth (ie flange used as fitting tool ) Still Leaks How can this be ? What can we have missed ? I have rebuilt LT 230's quite successfully. This has me stumped.
Ian

[justinc]

Don't take this wrong Ian, but he isn't using the plug up on the LH side of the transfer case as a level plug?:o I have seen this before. Adds about 1.5 litres to the case and will cause it to leak.

Other than that, what seal is he using? A genuine ('Corteco' brand) part number FTC4939 is the only one to use IME.

JC

[ibest]

Thanks Justin, both items worth checking, but right now my friend has been called out with the Rural Fire Service (heatwave here in Sydney ) so I cant ask him. Will post his responses when to hand.
Regards Ian

[ibest]

That update as promised Justin, the first couple of seals were after market,then he went to the genuine Corteco type. He used the filler at the back of the transfer box somewhere close to the handbrake cable. ( his description ) sounds right to me. He is going to try a 'Speedie sleeve' which if nothing else will tighten the fit of the seal. Thanks again for your advices. Regards Ian.

[feraldisco]

I have a leaking seal as well - from RAVE it looks like special tools are required to remove handbrake assembly to get to the seal. Anyone have any idea of the rough cost of outsourcing this job?