CJ5 Leaking from output seal Dana 20...2 seals later still chasing leak.
I don't know what to do, I have put 2 rear output seals in the last 4 months in my CJ5. It is the output seal coming out of the rear of the transfer case going to rear drive shaft. I pressure washed the tranny and found that it was coming from this point. I replaced it for the second time the other day and it is spraying fluid all over the exhaust and tub, and spraying all over the fuel tank. It is the correct seal, I also put it in correctly. What could be causing this????? It is driving me insane, the smell of it burning, as well as it soaking the underside of the tub. Could it be a scored yolk? The Jeep has a 4" BDS lift, and a stock Drive shaft. It does have a transfer case drop, and shims for the rear axle. I am at a loss!!!
Your yoke, is there a groove in it? Can you hang a finger nail in it? Is there a burr on the yoke that may be cutting the new seal? Does the shaft on the transfer case have bearing wear causing the yoke to have to much runout which will cause the seal to leak? A lot of questions. You may just need to go to NAPA with your yoke and get a Speedi-Sleeve to repair your yoke another new seal and be on your merry way.
the vent was fine, I removed and inspected the yolk, which showed minor wear, no burrs. There was no side to side motion nor up and down on the bearing. I'm at a loss...should I just replace the yolk...could the dust shield be eating the rubber seal? Could I eliminate the dust shield?
Its probably a worn in shaft groove on the yoke that is causing the leak problem. I had a similar problem after finishing the restoration of my Jeep and the yoke started leaking after driving it around. I'm a stickler when it comes to leaks and I seek them out no matter where they are coming from and make the necessary repairs to stop them no matter what the cost. I had to purchase a new yoke to stop it from leaking.
A small groove in the shaft that makes contact with the sealing surface will leak every time. My advice is to purchase a new yoke, use sealant on the splines before installing and coat the shaft surface with oil or Vaseline where it makes contact with the seal.