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40 Series transfer case oil leak help

Posted: Tue Jan 12, 2010 9:50 pm
by woodyjbh
Guys,

Well, somethings let go in my transfer case and i've started to have regular little pools of oil gathering underneath it. Its leaking from the area pictured below:

Image

Image

Now, the natural assumption is that there is an o-ring/seal on the shaft that has failed and needs replacing. I've already taken the bolt out and seen if theres any movement in the shaft but wasn't brave enough to pull hard in case something fell off internally.

So, the questions are as follows:

# Has anyone had this problem before?

# Is there an easy solution to fixing the leak?

# Am i going to have to remove the whole case to get to the o-ring from inside?

# Should I just buy a complete rebuild kit (Around $265 on ebay) or should i strip it then try and order the relevant bits individually??

# When I remove the case, is there any hints or tricks involved??

I'm a mechanic anyway so doing the job won't be a technical issue really but like any regular joe, I want to avoid doing the big job if I can.

Any help would be appreciated.

Woody

Posted: Wed Jan 13, 2010 6:22 am
by SIMMO84
You can replace the O ring by sliding the shaft out just enough to get the o ring.
If you go too far a thrust washer will fall out on the other end of the shaft. Easy job that has been done thousands of times before.