Transfer Case - Output Seal Leakage
No: 41/02/97/NASRef: WSM section 41
*Issue: 3
Date: 11/23/99*
PRIDE IV 4-08
Transfer Gearbox Output Seal Replacement
AFFECTED VEHICLE RANGE:
*RANGE ROVER (LP) All*
* indicates updated information
SITUATION:
TRANSFER GEARBOX OUTPUT SEALS LEAKING
Transfer gearbox output seals may be found to be leaking. If either the front or the rear output shaft seal is leaking, both should be replaced.
RESOLUTION:
REPLACE TRANSFER GEARBOX OUTPUT SEALS
*Redesigned output shaft oil seal kits are now available for the Borg Warner Electronic Shift Transfer Gearbox used on Range Rover. The new seals in the kits utilize an improved material and a twin lip seal design which incorporates an additional dust lip to ensure long seal life. The new seals are installed to a greater depth than the original seals. New Flanges must also be installed in conjunction these seals.*
CAUTION:
Use new tool LRT-41-013 to install the seals. (Do not use LRT-41-011)
PARTS INFORMATION:
*NOTE:
All of the parts necessary for this repair are now available in two kits. One is for the rear seal, and the other is for the front. The following part numbers are kits that include all parts referenced in issue two of this bulletin.*
*STC4380 Seal and Flange Kit Front*
^ STC3897 Flange Assembly - Front Output
^* 571970 Mudshield - Transfer box Oil Seal - Rear*
^ FTC4939 Seal - transfer box output
^ RTC6363 Seal - transfer box output flange spline
^ NY112041L Nut- nyloc - M12
*STC4381 Seal and Flange Kit Rear*
^* STC3244 Flange Assembly - Rear Output*
^ FTC4939 Seal - transfer box output
^ RTC6363 Seal - transfer box output flange spline
^ NY112041L Nut - nyloc - M12
WARRANTY CLAIMS:
41.20.51 Time 1.05 hrs.
Replace Front Output Shaft Seal
41.20.54 Time 0.85 hrs.
Replace Rear Output Shaft Seal
FAULT CODE: N
Normal warranty policy and procedures apply
REPAIR PROCEDURE:
REAR SEAL REPLACEMENT
1. Following instructions found in WSM section 41 remove rear drive shaft, parking brake drum, oil seal, and flange assembly.
CAUTION:
Use care in order to avoid damaging the seal installation area of the transfer gearbox.
2. Lubricate new seal lip with transmission fluid and install seal using tool LRT-41-013.
3. Carefully clean any oil found on the parking brake backing plate, shoes and drum.
CAUTION:
A new style flange must be installed on the front output shaft when replacing the seal.
4.* Install new output flange.
5. Replace rubber-sealing washer with transfer box output flange spline seal RTC6363.
6. Fit washer and Nyloc nut finger tight.*
7. Install parking brake drum and secure to flange with screw.
8. Adjust parking brake shoes and apply parking brake.
9. Tighten Nyloc nut to 220 Nm. (162 lbf.ft).
10. Reinstall remaining components as described in WSM section 41.
FRONT SEAL REPLACEMENT
1. Following instructions found in WSM section 41 remove front drive shaft, oil seal and flange assembly.
CAUTION:
Use care in order to avoid damaging the seal installation area of the transfer gearbox.
2. Lubricate seal lip with transmission fluid and install seal using tool LRT-41-013.
CAUTION:
A new style flange must be installed on the front output shaft when replacing the seal.
3.* Install new mudshield and flange.
4. Replace rubber-sealing washer with transfer box output flange spline seal RTC6363.
5. Fit washer and Nyloc nut finger tight.*
6. Tighten nut to 220 Nm. (162 lbf.ft).
7. Reinstall remaining components as described in WSM section 41.
8. Top off transfer gearbox with Dexron III ATF.