[Tpeterson]

I noticed a small leak coming from inside the outer rear flange of my NP241 transfer case. I first noticed this when I replaced my stock rear drive shaft with the Tom Wood Rubicon rear “CV” drive shaft. The stock shaft was sealed at the flange and when it was removed a good amount of fluid leaked out. There is a TSB covering this issue but the jeep rep refused to cover the cost of any parts.


My question is has anyone had experience with this transfer case issue and if so it is a complicated fix?

[WAC_Jeeper]

Are you talking about the little seal that is behind the flange nut? It rides on the splines, in the center of the output flange.

Or the shaft seal around the outer diameter the output flange when it goes into the back of the case?


Edit - it sounds like the seal behind the nut which holds the output flange on. Got any pics? If it is this seal, get a new seal (it looks like a miniture round saw blade), pull the nut off and slide the flange off. Replace the bad seal and put the flange back on. Be careful not to crush the seal when reinstalling it and lining it up with the splines. I always use some RTV also.

[Tpeterson]

That sounds about right…….the leak is coming from inner part where the nut is

[black03rubi]

You will need to replace the nut also, it is a one use only locking nut. The part numbers for the nut and washer are 04167924 and 04210973. The washer is the seal you need to replace. There is also a revised retainer housing available if the leak is coming from the rear seal.

-Andrew

[MarkTJRubi]

Originally Posted by Tpeterson

I noticed a small leak coming from inside the outer rear flange of my NP241 transfer case. I first noticed this when I replaced my stock rear drive shaft with the Tom Wood Rubicon rear “CV” drive shaft. The stock shaft was sealed at the flange and when it was removed a good amount of fluid leaked out. There is a TSB covering this issue but the jeep rep refused to cover the cost of any parts.


My question is has anyone had experience with this transfer case issue and if so it is a complicated fix?

I have exactly the same problem....what was your fix? I added a Rokmen tummy tuck, adj control arms, and Tom Woods drive shaft.

[Thean]

The best way I have found is to use some RTV with that splined seal.

If you flip the yoke to its face side, the splines will be looking up at you.

Run a decent fat bead of silicone around the inside of the splines.

Take your splined washer & use it like a squeege to push the silicone towards the outside of the flange. Just dont push it all the way. You only need it pushed in enough to get the splines started & the nut started on the threads.

Then use the nut to suck it down. It will push that RTV in there & it wont leak..... As long as you cleaned the splines good.

This works the same for any of the fixed output t-cases for the most part.

[ron746]

Mine leaked and pushed the seal out of the housing, found out the early ones didn't have a oil relief cut in the tail housing to let the oil drain back down, after I changed it mine has been fine, it was a mistake by jeep that they corrected in mid 04.