NP231 - New Rear Output Seal Leaks
I discovered a leak in the rear housing of the tcase. It was bad enough that the dirt and debris under the tcase was a wet sludge sitting on the skid plate, so I figured I should fix it.
I disassembled the tcase to the rear housing, put new gasket stuff on it, and then put it all back together.
For reassembly, I put in a new snap ring, rear output seal, and oil slinger.
The rear housing leak is gone, but now the rear output is flinging a lot of fluid. A much worse leak than the housing ever was. I took my time installing it, the edge is seated all the way around the lip of the rear housing, I made sure of that, and then spent another couple minutes tapping it a bit more, just to be sure. I suppose it could still be in wrong, but I don't know how, offhand.
I did some reading, and the likely culprits are that the shaft is slightly worn where the old seal was and conformed to it, where the new seal doesn't, or a defective new seal, but it looked good to me before I put it in. It had a bead of red lubricant around the inside already, so I didn't add anything before putting it on. It went on with no trouble, I didn't have to force it, and it seated snugly.
I'm just trying to get some idea of what is going on. I don't want to buy another seal just to have it leak as well. What are the likely mistakes I made? I know the assembly order is correct, it really only goes one way. (snap ring -> seal -> slinger).