TC input shaft seal fitting depth

[Graeme]

Can anyone advise the depth the transfer case input shaft seal should be? The WSM only refers to the special tool that sets the depth.

I had my L322's gearbox output shaft and TC input shaft splines re-lubricated and the TC input shaft seal replaced by the local workshop. However they appear to have made the same mistake they made with my D4 some years ago when its gbox was rebuilt wherein the seal was pushed in too far allowing oil to escape from a small hole normally covered by the seal. There isn't a lip for the seal so without the tool and no depth measurement, unless one is aware of the small hole it would be easy to push the seal in too deeply.
Hopefully the new seal will be fitted this week, what's left of it, as it's my only transport apart from my truck.

[PerthDisco]

Can anyone advise the depth the transfer case input shaft seal should be? The WSM only refers to the special tool that sets the depth.

I had my L322's gearbox output shaft and TC input shaft splines re-lubricated and the TC input shaft seal replaced by the local workshop. However they appear to have made the same mistake they made with my D4 some years ago when its gbox was rebuilt wherein the seal was pushed in too far allowing oil to escape from a small hole normally covered by the seal. There isn't a lip for the seal so without the tool and no depth measurement, unless one is aware of the small hole it would be easy to push the seal in too deeply.
Hopefully the new seal will be fitted this week, what's left of it, as it's my only transport apart from my truck.

What made you decide to get this done and were the splines dry?

My guess is that the seal should not go in deep enough to cover the hole. I’ve seen this on diffs where there is a hole (presumably a drain for splash) behind the seal and you have to be careful to insert it only so much but not blocking the hole.

Edit - it’s all described here;

Looks to me like 25mm is insertion depth.

DISCO3.CO.UK - View topic - Guide: Replacement of Transfer Box Seals

[Graeme]

Thanks but IMO accurately estimating the depth from the computer-generated drawing of the tool with no dimensions isn't possible. I wondered if someone had purchased the tool and had measured the depth.

The splines were re-greased because of the number of spline failures over the years due to dryness. Mine were found not to be dry and the splines undamaged but not much of a grease coating was left. The mechanic was doubtful that the grease would have lasted another 100K kms.

[PerthDisco]

Thanks but IMO accurately estimating the depth from the computer-generated drawing of the tool with no dimensions isn't possible. I wondered if someone had purchased the tool and had measured the depth.

The splines were re-greased because of the number of spline failures over the years due to dryness. Mine were found not to be dry and the splines undamaged but not much of a grease coating was left. The mechanic was doubtful that the grease would have lasted another 100K kms.

That’s interesting. We’re you just replacing the seal preventatively because you were in there?

Yes it has dimensions on the cross section drawing. I read 25mm for the depth.

You could put a depth mark on a socket and tap it in carefully.

Obviously they removed the old one without measuring?

[Graeme]

Sorry, I didn't see the measurements earlier. Thanks lots!

Yes, replacing the seal just because the TC was removed but perhaps futile as the output shaft seals seem to be the ones that leak.

Presumably the mechanic thought that the seal pressed against a ridge prior to its removal. I know that the workshop owner was involved in the 2nd go at the D4's TC but I don't think that the youngish mechanic worked there when the D4 was done but I expected the owner to remember. I had intended mentioning the seal depth issue to the owner when arranging the work but forgot then intended mentioning it to the mechanic who was to do the job but I didn't get to speak with him when the car was dropped-off.

[Graeme]

I was informed that the seal had been fitted too far in by a couple of mm and that the small hole wasn't spotted at fitting due to how the TC was positioned on the work-bench. The 2nd new seal was fitted at 25mm and doesn't leak.
Thanks again PerthDisco.