I have a 2004 ranger xlt fx4 level II with a 5 speed manual transmission. I have replaced this 3 times and everytime it gets a leak on the rear seal at the transfer case. once I take this on the hwy it seems to leak worse and eventually burn up the gears in the tranny leaving me with 4th gear. why is this continuing to happen? Is something else wrong that would be causing this?

 

Hows the transfer case end that goes into the trans. Is the bearing oit to cause it to vibrate and elongate the seal or is there a wear mark on the shaft the seal rides on that would cause it to leak. The transfer case is the same factor in all this so i would check it out really good.

 

has the output shaft of the trans been replaced where the seal rides? if not, it needs to be. If you have a Hurst shifter that removes the trans vent, or if the shifter is installed with gray RTV, this could do it to....dumb question, but why would you continue to drive it for it to run empty? it holds nearly three quarts, thats alot of leaking without topping it off

 

x2 on the output shaft. From what little i know about transmissions, I know they have to be replaced when a whole tranny goes.

 

I beleive the trans output shaft seal rides on the input of the tcase.

 

3 different units or rebuilt 3 times?

 

I'm assuming you mean Where the extension housing attaches to the trans? So since The M5ODs have dry extension housings, its probably the tailshaft seal leaking.

And you could have saved yourself 3 transmissions by simply keeping an eye on your fluid.

 

First of all. I bought this truck used and about 3months later it went out but didn't appear to be leaking that time. I replaced it with a rebuilt one and soon after that the clutch and slave cycl went out. I had that replaced and a few months later I noticed the leak at the rear of the tranny. I kept fliud in it as needed but it still went out shortly after that. The third one now I just bought it from a junk yard with 60,000 miles on it and had my mechanic put it in. After a short 80 mile trip 2 weeks later I noticed it leaking again. It did seeem to vibrate the shifter quite a bit once 70mph was reached as well. I took it in and had the fluid cked and it was still full. A few days later I drove it across town about 5 miles at 55mph when it went out and allot of fluid leaked out during that time.

 

The tailshaft housing IS dry on this trans. The transfer case is sealed and the trans is sealed.

If the truck is vibrating, this needs to be diagnosed. Remove one driveshaft at a time and see if the vibration goes away (this will require you to drive the truck in 4x4 with the front driveshaft in. If the vibration is the same with both driveshafts removed (one at a time) remove the transfer case and spin the transmission up to 50-60 MPH and see if the vibration is gone. If it is, replace the tcase