I am having problems with the local shop. The are not a diesel shop but I figured they could handle this. They have attempted to replace the output shaft seal two times. (From the transfer case.) Could someone tell me what they may have missed. It still leaks a little bit but not nearly as bad as before. The first time they just replaced the seal, it leaked worse than before I took it in. The second time they replaced the seal (I think) and some stopper like thing they mentioned. It still drips a little bit. (Spot the size of quarter.) I would like to know what the parts are that are in the transfer case or if there is a diagram available for me to look at or if this is the best that can be done for this problem. Sorry for not being more discriptive. I don't really know that much about what I am trying to decribe.

Cjthor,
2001, ext cab lng box, 4x4 HO, 78K

 

Front seal or rear?

Did the seal get damaged while being put in, or is the case scatched or burred somewhere cutting the seal?

Or is the enough of a grove on the shaft, and seal lip is hitting the same spot? Given the miles you have, I doubt that.

 

Correct me If I am wrong. You have the manual trans, than what they refered to as the transfer case. It would be the seal that is at the back of the transfer case where the shaft goes into the transfer case. I would guess this to be the back seal as I am assuming there is one in the front. They also mentioned some brass bushing, but they did not think there was anything wrong with that. This shop has done gould work on the car in the past, but I am begiing to have my doubts.

Thanks,
Cjthor,
01, leaky, HO 4x4 6 spd ext, 78k

 

No, it's not normal for the output shaft seal on the transfer case to -drip-. It -is- normal for a little bit of oily "haze" to build up on the case around the seal over tens of thousands of miles, because there's a fair amount of vibration there.

If it were me, I'd take the truck back to the shop for the third time and tell them they have one more chance.

There are a number of things it could be - damaged seal, damaged metal lip tearing into the seal, excessive vibration of the shaft, even too much ATF pumped into the transfer case, etc. Your shop's falling down on the diagnosis part of the repair, or they've just done a sloppy job and damaged something else themselves.

 

There are 2 output shaft seals. One for the front axle driveshaft and one for the rear shaft. You hadn't specified which one. That is why I asked. Theshaft that is attached to the tranny shaft is the input seal.

The rear one is easy to replace. Maybe they are being careless when sliding the driveshaft back in, tearing the seal. Or, there is a burr on the slip yoke.

 

I thought the rear was leaking on mine so I replaced it. The next day the leak was still there. Did a little more checking and found out it was the yoke that was bad. It was leaking right out the end of it. Replaced that and no problems since. If it is throwing fluid all over the underside of the truck check the yoke.

 

Thanks, you guys rock. I will try to post some picks. It seems like it takes a couple days of sitting before the drop hits the ground. Thanks again for all your insite.

 

Here is the link to the pic. I thought a pic would be better seeing as how I don't know what I am talking about most of the time. Any other input on what else could be causing this would be great. I went back to the shop and they agreed to look at it again, just have to find time to get it there.

https://www.dieseltruckresource.com/...php?photo=9780

Thanks,
cjthor, 01 HO 6spd, ext cab lng box 4X4, 79k