D20 leaking like a sieve

[Johnnyb]

I know I should pull the transfer case and put new seals in everywhere, but I'm anxious to get back on the road.

What do you suppose the chances are of getting it to leak less while it still mounted in the EB?

Drain it, clean it, change the front rear drive shaft seals, all the cover gaskets, etc.

-JB

 

[DirtDonk]

As long as it’s not leaking from the interface between the housings, that’s all you need to do. Just remove the covers and old gaskets from where it’s leaking, replace them and you’re on your way.

Another common area for you to check though would be the front bearing cover. There are shims in there and they don’t always seal perfectly.
You have to be careful though as those set the preload or tolerances on on the front output bearing. They are thin and also need to have perfectly flat and clean surfaces. You can’t manually clean them very well because some of them are paper thin and you will ruin them trying to wipe them.
But if they are leaking then to my mind it’s worth a little bit of that spray on form a gasket.
I try not to use a tube of silicone because the danger of damaging the seals or putting too much on and changing the tolerances is very high.
The spray on stuff can go on very thin and squeeze out when you re-torque the cover.