Outer Limits 4x4 Board

g'day got a 1998 75 ute and the transfer is leaking badly from what i think is the rear output shaft ( where the tailshaft bolts up to the back of the transfer) i have replaced the yoke bit and the rubber seal that sits just behind it and it is still leaking. im losing about 1litre every 2500kms any ideas fellas?
cheers

You probably need a balance tube between the gearbox and transfer. Basically unscrew the filler plugs and screw in some right angle fittings and join with oil resistant hose(make it longer and arch it up towards the floor).

You may also find that the breather on the top of the box is blocked too.

Bearing behind the seal may also be shot. Do the balance tube first though.

thanks guys has already had the balance tube put in and i replaced the breather also and still no change...

its not coming from around the idler shaft is it? mine leaks pretty bad from there too.

My hzj75 troopy does the same thing. In my case the oil is leaking along the output shaft inside the flange. It fills the space around the nut inside the flanges and throws out under centrifugal force as i drive. It makes a mess of the floor and fuel lines but the transfer is clean and it seldom drips on the ground. However i'm not losing that much oil. I have been told the fix is to drop the tail shaft, remove the output flange nut and washer, clean well and use one of the good sealing compounds inside the flange behind the washer. I haven't got round to it yet but it's on the list. To prove the point, slacken the 4 front flange nuts and you will probably release a small amount of oil.
LOL Ed.

zoltan which one is the idler shaft?

ed i reckon this might be the same problem as mine but mine seems to leak continually once the box has got to running temps and continues to drip badly once stationary.
cheers dickie

old ed wrote:My hzj75 troopy does the same thing. In my case the oil is leaking along the output shaft inside the flange. It fills the space around the nut inside the flanges and throws out under centrifugal force as i drive. It makes a mess of the floor and fuel lines but the transfer is clean and it seldom drips on the ground. However i'm not losing that much oil. I have been told the fix is to drop the tail shaft, remove the output flange nut and washer, clean well and use one of the good sealing compounds inside the flange behind the washer. I haven't got round to it yet but it's on the list. To prove the point, slacken the 4 front flange nuts and you will probably release a small amount of oil.
LOL Ed.

Just pull the flange out and put some sealant on the splines and put it back together. His one is leaking a lot though, probably wouldn't be able to leak too much through the splines and past the washer, nut and tailshaft.