Rebuilding X Type transfer case
 

Has anyone ever replaced the seals in the Transfer Case planetary drive? I purchased a new transfer case for my 2004 X Type but I must have torn a seal in the planetary drive when I installed it. I am getting transmission fluid coming out of the transfer case breather. I have searched several threads here but have not found anything.

If it's coming out the breather, then the odds are that you've overfilled it. From new - ie completely empty - it should have 600mls of oil, but when changing oil, to allow for dregs, it should be refilled with 550mls. If overfilled, it will continue to blow out of the breather until the level falls to about 650/700mls.

If the box is drained using the badly positioned drain plug, there will be 250mls left in the box, therefore requiring only 350mls to be put in to restore the 600 total.

I installed a new transfer case that was supposedly empty. I put 660 ml in it. I have driven it for two weeks and it is getting worse. I am going to check the transmission level to see if it is low and I am going to drain the transfer case to see how much comes out. But I really think a seal is compromised allowing transmission fluid to back into the transfer case.

Okay, I got the car in the garage this weekend and up on jack stands to check things out. I checked the transmission fluid level and it still seems to be at the full level so I do not think I have an issue with the seals between the transmission and the transfer case. Upon further investigation it does not appear that the source of the oil leak is the transfer case. So with the engine idling and me under the car with a light I see little oil bubbles coming from between the engine block and the oil pan. Obviously, I have a bad oil pan gasket. Too bad I did not notice this while I was changing the TC since it covers one of the oil pan bolts. So, it looks like I am going to have to spend another long weekend some day under the car pulling the TC to change the oil pan gasket. Gotta love a Jaguar

Yes,


To replace the two inner shaft seals that are inside the planetary gear you will need to remove the planetary gear assembly. The planetary gear has a shaft pressed into it. It is the shaft with the splines on the outside. To get to the seals you will need to press out shaft. To press out the shaft, simply spoon out the old seals from the non-shaft side. Once the seals are removed, you will see the face of the splined shaft. Take a socket large enough to cover the face of the shaft and press it out. Replace the two inner shaft seals and press the shaft back in place. A small press is all you will need. 12 Ton is plenty.


Be careful when pressing the shaft back into the planetary gear. If it gets cocked do not force it. Stop and set it up strait. Use some gear lube to press it in. It goes in easy and with minimal pressure.





Enjoy……

That sure is a pretty hard job to tackle. I'm planning to put a wet system in my Xtype so I might be rebuilding a TC (or having it done)...but transfer case be dammed...a kitty has gotta have its claws.

Cherry,
The rebuild was not so bad. Getting the Parts was another story all in its own. If you have ever built a transfer case, you will find this one to be very easy. if you have never built one before and are interested in doing the job yourself just take good pix. Also, when you separate the case, in addition to removing all Torx bolts from both sides of the case seam you will need to remove the big exterior nut that holds a stationary shaft in place.

Thanks Doc....but to be honest, I couldn't even take the wheel off to change a flat the other day. I just fly the thing....it's good learn about it though...shit I wouldn't mind drinkin me a cerveza while watching the job get done..lol

I totally understand. Enjoy your rides.

It looks like it would be nasty to get the old seals out. I'm looking at them now. Do they have to be destroyed to get them out?

X-type is the only car in the world, which has turning wheel studs problem. I welded 3 studs today and it was not easy because I have $25 welder (or maybe I need welding lessons :))

https://www.jaguarforums.com/forum/a...ine=1401308558


https://www.jaguarforums.com/forum/a...ine=1401308558

https://www.jaguarforums.com/forum/a...ine=1401309509


With the seals out. There is what appears to be RTV in the joint between the two shafts. You can see some of it in the splines. That would make sense as that is the point at which the transfer case gear oil and transmission fluids are separated.


Now to find the seals. They are stamped Ford and I haven't located them yet.

This is about all you find when searching that part number; where to buy transfer case seals - Jaguar Forums - Jaguar Enthusiasts Forum


Do you have a source Dr. Jag?

39.65 mm 1.561 bore diameter, where the seals go.

Do you have transfer case repair manual? I would like to see parts diagram, if it is possible.

I don't have a transfer case manual, I don't know if they exist. I haven't seen a parts diagram either. The factory seems to have effectively locked down practically all repair information on the transfer cases.

This might help in the absence of anything else!

No,
Just as you said, Ford made the seals prepriority.
There are two ways to beat Ford. You can shim down to the next smaller size or bore up to the next larger size. Either way you go up or down, there are off the shelf seals that are better than the Ford seals. As for a repair manual. There is none. Take the case apart with good photos during the process and reverse the process accurately with exact bearings. Make sure you seat all bearing races completely. Let me know if there is more you need.