Gen 1 Transfer Case Output Shaft Leak

[MBZ300CD]

My first thread.

I was planning to fix the leak over my transfer case at the output shaft.

When I removed the companion flange it was dry inside the splash(?) cover/guard. When I removed the drive shaft a bunch of gear oil came out of the end. Also there was a bunch of orange RTV on the bolt, washer and spline for the companion shaft. This is before removing the companion flange. So it looks like the seal was good, but why the RTV and why is the oil leaking out of the spline? Is there some part missing? Is it normal?

Additionally the transfer case filler plug head is kind of stripped and doesn't want to come out. Is there any other way to re-fill the transfer case?

Any thoughts on these issues?

help

Thanks

 

[Dropzone]

so gonna say the RTV sealant you found was probably a half ass fix by a previous owner. i have had several cases apart over the years and never ran into that.

pull the t/c lever and fill from the top..though it would be best to try to get that stripped fill plug out since you fill it to capacity which is when it starts draining back out the fill hole.

 

[RAD4Runner]

I plan to do that soon.
I think the RTV is part of the re-assembly process.
Please refer to Grego's thread on Yotatech:
Rear oil seal on transfer case - Page 2 - YotaTech Forums

 

[joeynational]

Yes, the RTV is required and normal. So is the oil coming out after you remove the flange.

 

[Dropzone]

I think the RTV is part of the re-assembly process.
Please refer to Grego's thread on Yotatech:
Rear oil seal on transfer case - Page 2 - YotaTech Forums

Yes, the RTV is required and normal. So is the oil coming out after you remove the flange.

interesting, i have never seen the RTV on the putput flange and haven't used it when replacing the output seal..have not had a leak back there yet...guess I have been lucky so far

 

[RAD4Runner]

interesting, i have never seen the RTV on the putput flange and haven't used it when replacing the output seal....

So I looked at The Good Book and found out RTV is not required. Perhaps it's just an optional / extra measure that Grego and others did which did not hurt.

 

[MBZ300CD]

I plan to do that soon.
I think the RTV is part of the re-assembly process.
Please refer to Grego's thread on Yotatech:
Rear oil seal on transfer case - Page 2 - YotaTech Forums

The images from Greg's thread look just like what I found. Thank you for posting the link to it. I had gone to the dealer parts people, but they weren't able to help.

I appreciate everyones attention to my call for help.
Thanks, I can now move forward.

 

[Gone4broke]

New user so I can't post my own thread yet and this is the closest I've found on here to my problem.

Front output seal is leaking and I'm just wondering if anyone has any tips on changing it out. there are a ton of write ups for the rear output or for the front for 3rd gens, however, on the first gens that cross member is right in the way of the front output shaft.