This week I changed the rear output oil seal on the transfer case. A couple of weeks ago I found an important leak on the floor, so there was no other culprit than this seal (so I thought). Since I had a spare one, I decided this week to do the messy job. Unfortunately I didn't take any pictures. My camera was down and was afraid of using my phone.
Once I separated the arbor flange, about an ounce of oil came from inside the recess between the companion flange (#39) and the arbor yoke-flange (not shown). I dismantled the e-brake, the arbor, and then found that the nut with the cotter pin was slightly loose. Took the flange out and then the seal.
After careful inspection of the seal, I determined that the leak was coming through the spline of the transfer axle and the companion flange, since the seal was still with the grease I've applied when I serviced the unit some 18k miles ago. This seal has double lips (one for oil inside, and one for the water outside). The grease in between had no traces of oil. See the picture below with the place where the oil was leaking.
I had put the last time some silicone compound on the the companion flange, before placing the nut. The nut is actually what seals everything. I probably didn't torque it properly that time and little by little some oil started flowing into the recess between the flanges.
Transfer Case Leak.jpg
I ordered the following seal from eBay just to have in stock for future use. The same seal is used in the two output shafts of the transfer case, and at the pinion side of each differential (4 total) :
AVX Shaft Oil Seal TC50x73x12 Rubber Lip 50mm/73mm/12mm metric (use this for the search)
http://www.ebay.com/itm/AVX-Shaft-Oil-S ... 5d60384466It's not double lipped as the original (to keep oil in, and water out). It does have an outer lip that will keep dust out. Will work if you're not fording any streams.
I have added the info of this seal in the thread
Seals: transfer case input-output, pinion.
viewtopic.php?f=24&t=2665&p=36547#p36547Torque for the companion flange nut:
69 - 87 lb-ft (93 - 118 Nm)
All these years my e-brake band was soaked in oil that I thought was migrating from a leak in the rear seal of the engine. That was probably only a tiny bit of all the oily mess. I thoroughly cleaned the brake band. Need to adjust it properly to see if it will work or not.
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