Drivetrain - Tranfer Case Rear Output Flange Oil Leak
XT308-01X-TYPE
DATE 03/03
MODEL
2002 MY
X-TYPE
VIN
C00294-D01489
Oil Leakage - Rear Output Flange Of Transfer Case - Repair Procedure
Issue:
Some 2002 MY X-TYPE vehicles, within the above VIN range, may experience oil leaking from behind the nut securing the rear output flange of the transfer case.
Action:
On a customer complaint basis only, if an oil leak is evident from between the transfer case rear output flange and driveshaft front Constant Velocity (CV) joint, or from the rear of the driveshaft front CV joint boot, follow the workshop procedure outlined below.
WORKSHOP PROCEDURE
1. Raise vehicle on twin post lift.
2. Mark the orientation of the driveshaft front CV joint to the transfer case rear output flange to ensure the same orientation when reassembled.
Warning:
Oil may drain from cavity when the driveshaft is disconnected from the flange.
3. Remove and discard driveshaft front CV joint to transfer case rear output flange securing bolts and locking links (Illustration 1).
Caution:
Do not allow the driveshaft to hang from the center bearing/joint as damage may occur.
4. Displace driveshaft front CV joint from transfer case rear output flange, remove and discard gasket and secure driveshaft to one side.
5. Use suitable securing bolts to install special tool 205-053 to transfer case rear output flange.
6. Remove the securing nut for the rear output flange of the transfer case.
Note:
Do not displace the flange from the output shaft.
7. Remove special tool 205-053 from transfer case rear output flange.
8. Using suitable solvent/cleaner, remove all traces of oil from transfer case rear output flange and exposed threads of output shaft.
9. Apply sealer (C2S 12099) to area of transfer case rear output flange where securing nut seats (Illustration 2).
10. Use suitable securing bolts to install special tool 205-053 to transfer case rear output flange.
11. Apply sealer (C2S 12099) to mating face of transfer case rear output flange securing nut (Illustration 3).
12. Install the securing nut on the transfer case rear output flange and tighten to 160 Nm.
13. Remove special tool 205-053 from the transfer case rear output flange.
14. Remove and discard grease from driveshaft front CV joint.
15. Repack driveshaft front CV joint with two sachets of grease.
16. Install new gasket and align driveshaft front CV joint to transfer case rear output flange.
17. Install new locking links and driveshaft front CV joint to transfer case rear output flange securing bolts and tighten to 44 Nm (Illustration 4).
18. Lower twin post lift.
Parts Information
Warranty Information:
Warranty claims should be submitted quoting the information found in the table.
This will result in payment of the stated time and, where applicable parts/miscellaneous expense codes as listed.