Thread: Transfer case woes

Ace - That is a very common leakage point. You have to remove the T/C for access. If you can do that, then you are home and hosed. The o rings are replaced by moving the shaft either way just far enough to change the o rings. Do NOT push the shaft all the way out, things will fall apart internally if you do. While you are at it, replace the gearbox output seal and the T/C input seal. We charge about $580 to do the entire job, which will give you an indication of how hard it is (seals and O rings are maybe $25 - $35 worth, plus oil - mostly labour).

From Alan's discription it might be leaking from the intermediate shaft o-rings.
You might be able replace these without disassembly of the box.
But as already stated only push it out the minimum required to change the o-ring.
I have not done this myself but it looks feasable from looking at the overhaul manual.

Sound like its needs a good clean to determine the leak location first.

I am just going to fit an entire seal kit, only cost $45.

I have everything undone but i cant separate the transfer case from the gearbox. Once i have undone all the nuts and bolts from around the outer edge is there anything else that might keep them together? Matt

They will stick together and be a bit hard to get started. Try gentle persuasion. Make sure all the linkages and wiring are disconnected. Don't drop it and make sure you don't damage any new seals on reassembly.

Thanks Bigjon i missed one of the bolts was hiding under some mud. It is now out and on the floor ready to be fully cleaned before recieving new seals and being put back in tomorrow. Matt

Hey Ace,

When you put the o rings on the intermediate shaft, make sure you use a smear of 3 Bond or Hylomar or really good gasket sealant to give it (the sealing) a hand. One of the seals (rear one?) is in the case and the other on a recess on the shaft. Do both. Put a bit of sealant on the back(case side) of the washer behind the shaft fixing nut, and a "crown" of sealant over the front face of the intermediate shaft just clipping the edges of the case.

Reassembly of T/C to gearbox - make sure the t/c seal runs on the sealing collar, and don't dislodge it on assembly.

How do I know? Took me three shots to solve all the tricks. 8-(.

HTH

Pete

Thanks guys, well its all back together i didnt do all the seals, i only did what was easy to get to and what couldnt be done whilst in the vehicle, i figure i wont disturb the seals that arent leaking until they leak, i will cross that bridge when i come to it. i replaced the o-ring and put it back in (i didnt use any sealant hope it doesnt leak) and i replaced the gasket between the CDL and the main part of the TC because it might have been leaking aswell i couldnt tell 100% whether it was the o-ring or that so i did it to.

Its now back in the car and mostly hooked up i gave up just after lunch cause i had a massive headache so will hook up the shafts and take it for a spin before i put the interior back in, make sure there are no leaks and then put the rest back together. Job done.

For those thinking about it, its not that hard of a job, getting the bitch back in was a mongrel of a job. Matt

i will be out of work soon.....if you keep that up.....