Transfer case front output seal

[pjb]

Folks,
Anyone know how hard it it to change the front output seal on a 3.5V6 transfer case? Mine has sprung a fast leak...
Also, presume it takes regular hypoid gear oil?

[-Scott-]

Is it the seal, or the welsh plug in the end of the yoke? Mine's sprung a leak twice now.

[pjb]

Hmm, that would be preferable. How can I check?

[-Scott-]

Good question. Have a close look at where the oil is, and have a think about how it got there. If it's the seal leaking then there should be very little oil over the uni joint itself. If it's the plug, then the oil is coming out basically at the uni joint, and there will be much more oil over it.

On both occasions that mine failed, once I knew that these plugs have a reputation for leaking, I thought it was obvious that it was coming through the plug, and not the seal. Having said that, I haven't seen a leak past the seal.

[pjb]

Cool, thanks for that Scott. The back of the plug is looking pretty dry apart from grease... Must be the seal
Might have to drop it at the mechanic.

[pjb]

All fixed... New output seal and no more leaks. Turns out you can just lever the seal out and press a new one in.

[NJV6]

Any tricks to getting the seal out? I had a wee go but failed without bending the output guard. Might try putting a screw through it... Transfer case oil looked a bit doubtful I reckon you musten't be able to fully drain it as place to bolt the PTO to is lower than the bung!!

[pjb]

Umm, struggling to remember what it looked like. Took the prop-shaft out for a look-see, but then got the shop down the road to replace the seal.
Doesn't the guard come away with the prop-shaft, as in, it's joined on to the back of the uj?
Looked like they levered it out (the old seal looked quite bent up).

Oil was the colour of milky tea when I drained. So I filled it up, drove it around a bit, then dropped it off at the shop for the seal replacement - hopefully will have diluted what couldn't be drained.

[date]

I am interested if anyone has replaced an input seal to the transfer case. I had the oils changed just before I went away for a trip and the transfer case was seriously overfull and the gearbox (manual) was underfull. I expect that it was only about 500 mL down, but it had obviously leaked oil from one to the other. Is it possible to repair it as Toyotas do ie put a hose on the gearbox and transfer case filler plugs and join them up? Otherwise, what is involved in getting to replace the inut seal?

[NJV6]

Got my output done, levered it out with a 90 degree screwdriver then bashed the new one in with some left over 40mm pipe