Thread: Leaking transfer input on D2...

If the leak has been a persistant one. The end of the shaft may have worn the the carrier hole on the housing. The O rings won't seal properly causing the leak even with new O rings. There might be a short term fix, not sure. I had the same drama until I got MR automotive to install a hardend carrier. Never had a leak again. It means taking the box out and maybe an engineering place could do it for you. That is if the carrier has been worn. Good luck mate.

Thanks Dave1,
Can you describe a little more where the O-rings actually are? And the carrier? I'm used to the old series stuff! Whats's it take to install a new carrier?
Cheers,
Dave

Dave,

Check out the transfer case pictures on RAVE 2. The o rings seal the intermediate shaft. The lipped seal fits to the front of the transfer box where the input shaft mates with the input gear in the transfer box.

The tfr box has to come out for a good repair on the intermediate shaft. You'll see in the RAVE pics where the shaft COULD wear the case, but I wouldn't be seeing it, frankly. I recall other posted info about sealant being applied to the o rings on assembly - could be on here somewhere.

I've done plenty of intermediate shaft seal repairs, and have had success with a quality sealant used on the casing hole / o ring interface. Your fettler will see what is meant. I also ensure that the new stake nut and carrier plate are well sealed. Is there a crush tube on the intermediate shaft to provide bearing preload? It'd be good to check the pics.

The insertion of the front input shaft seal should be done carefully, so that the seal doen't end up in exactly the same place in the casing as before. +/- 2 mm on the seal position is adequate to ensure the seal runs on "virgin" shaft.

On reassembly of the tfr box to the main gearbox, make sure that the input shaft DOES NOT contact and therefore damage the nice new input shaft seal.

HTH and good luck in passing on the eggs to grandma!

Pete