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I recently got the motor/trans/transfer case installed in the chassis of my truck (in my build thread). I filled the t-case with fluid to the bottom of the threads of the fill plug tonight and it started running out of the bottom of the front drive shaft output where the yoke fits into the bearing retainer. I replaced all seals in this while it was out. I can't remember if there was a seal on that one though. The Haynes manual doesn't show one. Could I have just over filled it? After the leaking stopped, the level was well below the bottom threads of the fill plug. I dread ripping this apart again, but it may have to be done. Does anyone know for sure?
And sometimes even when you replace seals for yokes, the you have to either by a new yoke, or sleeve the old yoke, so that it fits snugly inside the seal. Another culprit for leaking transfercase seals is worn out bearings which allow the shaft to rotate in a non concentric fashion which in turn wallows out the seal causing a leak.
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