Putting the old oil back in reminds me of a dog lapping up his own vomit. Gross! Would a higher viscosity new oil do the trick? It would be thicker but without all the debris and grime.

 

The problem now is that I just called and found out they can't find the right size seal. They already took the old one out and said it is no longer usable after being removed. The one that originally was delivered was the wrong size and he said that he now has 2 more which are also the wrong size. He said he is having the dealer call Jaguar NA to figure it out and that there is no part number on the old seal.

Meanwhile, I wanted to confirm that the cause wasn't something else, like overfilling. I asked if he knew about the vent on top and he said he did and that he had checked to make sure it wasn't leaking so it's definitely the seal.

My question now is: does anyone happen to know the part number of the right side output seal for an '05?

Also, does anyone have pictures of the '05 redesigned transfer case? How different is it from the original design? And, does it still have the vent?

 

Here's the latest update. We found out today that the first seal sent from the dealer was the one for the rear output. The next two we still have no idea what they are for because they are the correct shape but a different size. I suspect those may be for the older transfer case.

We tracked down the proper part number and ordered the part. It should be in by Monday morning and I should be able to pick the car up around noon.

Hopefully we're set now so I can start working on my electrical problem...

 

Goodluck! I hope it all works out. Not having your Jag for a week is tough, I know.

 

Finally got it back today

I still notice a burning smell but I'm assuming at this point it's either overfilled or some is still on the exhaust from last time.

Does anyone know if the '05 transfer case also has a vent for overflow or else how does the excess escape? How long should I wait now before it reaches the proper level?

 

Drive it for 2 weeks and it should go away. I think the common consensus is that the 05 case does in fact have a vent, although it might not be the same size as the 02 cases vent because the 04+ cases don't get as hot without the viscous coupling

 

Yeah, from looking at the parts catalog I can see the vent is a part.

I'll report back after two weeks on the smell. I think it may have been you who mentioned on another thread that not all 600ml comes out but most places put 600ml in since they don't think about what's left behind. Pretty sure that's what I'm dealing with here.

Hopefully the seal they replaced before actually was bad. That was a $200 bill and a week and a half without my car that I didn't want