Outer Limits 4x4 Board

Have made a couple of attempts to fix this damn oil leak in the last couple of months and no success. Before i pulled the box out to put the diesel in, the front output shaft seal was leaking and the rear was fine. replaced all the seals when the box was out, now the front is fine and the rear output shaft seal is leaking.
Have since thrown another new seal at it and it is still leaking oil, couple of drops on the driveway after a long drive.
Was pretty careful installing it last time, polished the output shaft with fine wet and dry sandpaper, lubed everything up before install, held back the cover that sits on the back of the gearbox so i could watch the lips on the oil seal when putting the tail shaft back in... running out of ideas
Vaguely remember when i first bought the thing they had to do something with the rear extension housing (which houses the rear oil seal) as it was leaking somewhere... think it was a bit of a known problem?
Anyone have any tips on what it could be or better ways to install it the seal/output shaft?

Cheer's, Ben

A common problem is the welsh plug in the slip yoke on the tail shaft. Oil leaks past the welsh plug and over the uni joint.

Have a look at Transmission Oil Leaks (now added to FAQ. )

Mine started leaking up the Cape. Removed the shaft, removed the uni joint, cleaned the area around the welsh plug and applied 24 hour Araldite to seal. Levelled the yoke in a vice to ensure the epoxy set evenly. No problem since.

Cheers,

Scott

Yep Scott is correct I discovered this problem after numerous oil leaks and replacing seals even put a Speedy sleeve on the front slip yoke and it still leaked until I discovered the internally leaking welch plug and plugged it with epoxy.
You can also adjust the tension of a leap seal by removing the internal spring uncoiling it and snipping a bit off then re-installing.
I had to do this recently after replacing 2 seals to stop my right front axle from leaking.

Thanks for the replys, will check out the welsh plug and let you know. So when the welsh plug leaks does the oil apear to be comming out around the C.V joint area (my tail shaft has a C.V joint at the front not a uni joint), not sure if you guy's have the same?
The oil seams to be spread out pretty well but also concentrated directly below the flange where that steel covers fits up to the back of the gearbox, which always makes it look like its the oil seal.

CV joint ??
I've never seen or heard of a CV joint instead of a uni on a Paj front propshaft. Is this from the factory ?
Yes it would appear like you say. The oil will leak through the welch plug and past the arms on the slip yoke and end up being flung around by the uni (or in your case CV).

Yeah not talking about the front prop shaft, what i was saying in the last post is i have a C.V joint at the front of my tail shaft, (where it slips into the back of the gearbox). There is a uni joint at the back of the tail shaft where it bolts up to the rear diff flange.
So is this the same setup on your paj?

NLShorty wrote:Yeah not talking about the front prop shaft, what i was saying in the last post is i have a C.V joint at the front of my tail shaft, (where it slips into the back of the gearbox). There is a uni joint at the back of the tail shaft where it bolts up to the rear diff flange.
So is this the same setup on your paj?

I have a pair of uni joints.

damn i got a C.V joint, must be a NL shorty thing?

NLShorty wrote:damn i got a C.V joint, must be a NL shorty thing?

You poor bugger.

Wanna swap shorties?

Can you take a pic of this CV ??
I'd like to chase it up.

The 3.5 SWBs have a CV, I got 1 with the locking diff I bought
J Top

Yes I've just been sleezing around in the CAPS programme and yep Challengers have them along with Gen 3 models.
Some have front and rear propshaft CV's instead of a uni at the slip yoke ends.
Looks like they have the circlip set up exactly like the IFS front axle spline locks into the diff side gears.
Very interesting (scratcing chin)........................

I got one factory..... But the weep is aftermarket.

Yeah i got an after market weep to, get your's from repco or super cheap?

Scott, might pass on the swap this time, although yours is a nice rig, maybe you should trade yours on a new one when they come out then we can swap

I get a slight rumble when in constant 4wd. maybe the CV is a fix for this.

iv got problems at the moment with my transfer, the front tailshaft is leaking dramatically from the transfer end, is wasnt too bad, got the seal replaced and the welsh plug soldered up and when filled up again it leaks worse than before. I understand its leaking worse than before because its got more oil in it, but that still means i havent fixed the problem, i lost about 1.5L overnight sitting idle in the driveway....dad was stoked

im about to put a new uni and yoke in it??? is there anything else im missing here??? is the new uni and yoke the way to go or not....

god i hope so, not really enjoying this leak, atleast i got the batteries done

dean

Zute wrote:I get a slight rumble when in constant 4wd. maybe the CV is a fix for this.

Zute, this shouldn't affect when in 4WD as it is on the rear tailshaft.

There have been a few threads about more noise when running in 4WD, I have noticed it as well, at about 2300Revs.

It might have been on the Pajero club forum that there was dicsussion about it, I don't notice the noise now over the seat rattles, exhaust, MT tyre noise etc etc...

klrevo wrote: i lost about 1.5L overnight sitting idle in the driveway

park on a really steep downhill.....?