208 transfer case problems

[firemedicsafd]

I have a 208 in my k5 right now. The driveshafts are balanced and the correct length. I replaced both output shaft seals in the transfer case a week ago. Correct numbers and looked like what came out. Right after I got the seals done I took the blazer to training towing a golf cart on a trailer. Once I got to my destination, I found the front seal leaking again just as bad as it was before. Everything looked good when it came out. Nothing out of round. My thought is the problem is because of the rod that goes on the transfer case and bolts to the back of the block. I think the missing rod is allowing the transfer case to torque up causing the front shaft to push against the seal. What do y'all think? I'm going to pull the front shaft to get home and we will see what that does.

The rod became missing when my transmission was rebuilt. Otherwise it would have been put back on.

Thanks for any help!

 

[JanneB]

Has the seal made a groove in the yoke?

 

[firemedicsafd]

No groove. When I pulled it I cleaned the yoke and that involved making sure the seal surface was smooth. It came out with a rust ring on it. It buffed out to smooth with no groove noted

 

[firemedicsafd]

On a confirmation note, when the seal was put back in, it didn't leak even with the front drive shaft installed. It started leaking when I hooked the trailer up and started towing with it. Further evidence that I think the rod being gone contributed to the issue.