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Old 03-15-2012, 04:42 PM   #1
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Leaking tcase after sye

Just put on the first 20 miles or so after installing the SYE. No vibes, I eyeballed the pinion angle till I found my angle finder, pinion=15* and the driveshaft was at 16* so I'm on there.

I got out and double checked for leaks and it's leaking pretty bad at the speedometer gear housing, I have it tightened down pretty good so I don't think it's loose. I'm wondering of maybe it's overfilled? I put in 1.5 or so quarts and the manual I saw says it's got a 1.1qt capacity. Anyone have any ideas on why it'd be leaking and what to do to stop it?

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Old 03-15-2012, 05:07 PM   #2
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You jacked the o ring...

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Old 03-15-2012, 05:13 PM   #3
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Yup the O-ring probably got shredded, i had to replace my speedo gear i shredded 2 of the damn things and the dealer was the only place i could find one that would fit correctly.
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Old 03-15-2012, 05:23 PM   #4
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Damn, alright thanks, I'll keep an eye on it for now till I can find an o ring, I'll probably end up buying 2 just in case I break it again.
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Old 03-15-2012, 06:31 PM   #5
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I cleaned it up and went to look for a o ring with no luck, got home and it was leaking from the rear output seal as well so i cleaned it up again and drained some fluid out (just to the point it wasnt leaking frol the open fill plug) and drove some and it seems to have stopped. Hopefully it was just a little full
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Old 03-15-2012, 09:42 PM   #6
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Drove it some more tonight, and its still leaking out of both the speedo housing and the rear output shaft... I'll track down a new o ring tomorrow for the speedo housing. But what should I do about the rear output shaft seal? I guess I'll have to contact rugged ridge and see what they can do about it, seeing as its supposed to have a warranty.
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Old 03-15-2012, 09:56 PM   #7
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Could be an o-ring or seal. But it sounds to me like you plugged the fluid drain passage for the housing with silicone when you attached it.

This would cause the housing to fill with fluid and leak.
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Old 03-15-2012, 10:06 PM   #8
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Quote:
Originally Posted by ipleadda2nd
Could be an o-ring or seal. But it sounds to me like you plugged the fluid drain passage for the housing with silicone when you attached it.

This would cause the housing to fill with fluid and leak.
I didn't think of that... I don't think I did, I was pretty careful to not over do it with the silicone, but that would explain it leaking out of both seeing as the O ring looked to be in good shape still.
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Old 03-15-2012, 11:35 PM   #9
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Where is the fluid drainage route? I was thinking it was where the rod was, which makes sense seeing as the silicone surrounded it after install. But that doesn't make sense. My guess is it's that hole in the plate?
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Old 03-16-2012, 10:06 AM   #10
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Before you attach the rear output housing you apply silicone to its perimeter. Make sure you do not get any silicone in the passage the red arrow is pointing to. It's that little channel that is recessed between the machined surfaces.

I hope this helps you!

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Old 03-16-2012, 02:42 PM   #11
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Ended up cracking the tail off and cleaning it up, made sure the drain route was clear of silicone. Ended up with a new speedo gear O ring and having to trim off some of the end of the gear with a file so it would seat all the way (that was my problem on the speedo leak)

Emailed rugged ridge and they are sending me a new rear seal for the tail since its still leaking there.

Really satisfied with the customer service at rugged ridge, they responded to my email and sent out a new seal a couple hours after I emailed them.
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Old 03-16-2012, 03:07 PM   #12
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Quote:
Originally Posted by Jeep_guy3 View Post
Ended up cracking the tail off and cleaning it up, made sure the drain route was clear of silicone. Ended up with a new speedo gear O ring and having to trim off some of the end of the gear with a file so it would seat all the way (that was my problem on the speedo leak)

Emailed rugged ridge and they are sending me a new rear seal for the tail since its still leaking there.

Really satisfied with the customer service at rugged ridge, they responded to my email and sent out a new seal a couple hours after I emailed them.
If I remember correctly, the RR SYE is similar to the AA one. If so, it may use the same output shaft seal. If that is the case, you can always buy replacements locally using these part numbers:

National seal # 3946 or Chicago/Rawhide number CR 18662

I know RR is sending you a new one, but just for future reference those numbers are always handy to have in case you end up needing one down the road.
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Old 03-16-2012, 03:10 PM   #13
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Quote:
Originally Posted by geiman

If I remember correctly, the RR SYE is similar to the AA one. If so, it may use the same output shaft seal. If that is the case, you can always buy replacements locally using these part numbers:

National seal # 3946 or Chicago/Rawhide number CR 18662

I know RR is sending you a new one, but just for future reference those numbers are always handy to have in case you end up needing one down the road.
Thank you for the info! I may buy one tomorrow so I can get this fixed.

Question? I read that the spring around the seal is supposed to be on the INSIDE? Is this correct? If so then mine was put in backwards at the factory cuz its on the outside.
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Old 03-16-2012, 03:12 PM   #14
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Off the top of my head I can't remember and unfortunately I'm nowhere near my Jeep right now. RR or AA should be able to answer that quickly for you.
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Old 03-18-2012, 03:30 PM   #15
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Yes, the spring is suppose to be on the inside. I can't believe they put it in backwards and it got through quality control.
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Old 03-22-2012, 04:50 PM   #16
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Quote:
Originally Posted by ipleadda2nd
Yes, the spring is suppose to be on the inside. I can't believe they put it in backwards and it got through quality control.
I just got the replacement seal from rugged ridge in the mail and it has a spring on both sides...

Any write ups/tips on how to swap this seal out?
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Old 03-23-2012, 10:12 AM   #17
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IDK. Can you post a pic?

Sounds like it looks different than mine. Are you talking about this seal?

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I had this output shaft seal leak after 500 miles after installing my TeraFlex SYE.

Here's my post:
http://www.wranglerforum.com/f5/sye-...es-104639.html

Turns out the seal wore away because I had drivetrain vibrations due to too much pinion angle (7 degrees). I could barely feel it. Once brought down to 1% and replaced seal, I haven't had the issue again.
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Old 03-23-2012, 12:20 PM   #18
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It looks like the same basic concept, only yours has less rubber then mine. I cleaned up the oil leak yesterday to see if it magically stopped haha haven't driven it yet.
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Old 03-23-2012, 02:15 PM   #19
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Cool. I hope someone chimes in that knows what's up.
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Old 03-23-2012, 07:25 PM   #20
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Cool. I hope someone chimes in that knows what's up.
How'd you change yours out? I'm assuming I'm gonna have to pull that tail housing and push it out from the inside out, then press the new one in and reinstall the whole thing? Did you find a replacement bushing/seal for the yoke or just use rtv? I'd rather not use rtv if I can avoid it but doubt oreillys or autozone will have one, maybe napa?

Thanks
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Old 03-23-2012, 07:37 PM   #21
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To replace the seal, it's pretty much just remove it however is easiest and press the new one in. You can replace the seal without removing the tail housing, but of course it will be easier if you remove it. I'd try it first without removing the housing, but if it gives you problems you know what you have to do.

The rubber star washer you can get at the dealer, and you can also get another nut for the yoke. The nuts are supposed to be one-time use. However, if you can't get to the dealer for replacements you can use RTV instead of the rubber star washer and put blue locktight on the nut for the yoke. If you want to get replacement parts from the dealer, these are the part numbers: 4210973 for the nut and 4167924 for the star washer.

I've reused the star washer (but added some RTV) and reused the old yoke nut without issue. Not saying that's what you should do, but that it is possible. If you do use RTV, just don't go crazy. If you get RTV into the tail housing, it can get ground up and clog the oil pump filter screen.

There is a common problem where things don't seal well at the rubber star washer/around the yoke. I had this problem and fixed it by simply removing the yoke, adding some RTV at the yoke end of the yoke splines, and reinstalling things nice and tight.
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Old 03-24-2012, 09:51 AM   #22
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How'd you change yours out? I'm assuming I'm gonna have to pull that tail housing and push it out from the inside out, then press the new one in and reinstall the whole thing? Did you find a replacement bushing/seal for the yoke or just use rtv? I'd rather not use rtv if I can avoid it but doubt oreillys or autozone will have one, maybe napa?

Thanks
Remove the yoke nut, then the yoke. There should now be a space between the output shaft and seal. Get a seal puller from harbor freight, auto parts store, etc, and pull it out. Take care not to scratch the housing's seal mating surface.

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What I did was take the seal to Lowes or something and match up a piece of PVC pipe to the same outside diameter. Then use a hammer and lightly drive the seal in uniformly. Some seals come with a solidified silicone on their surface, some don't. If not put on a smear of RTV as seen in below pic.

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As far as the replacement seal.... Get a part number from the manufacturer of your SYE. It's probably a common seal and can be found somewhere locally.

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