How much, if any, gear oil should leak through the transfer case rear output seal. When I removed the drive shaft gear oil poured out. There was High temp RTV sealing the drive shaft to the yoke, and that seemed to work because the yoke was dry before removal. What do you guys think about just resealing the drive shaft the same way and calling it a day? Does the transfer case rear output seal need to be replaced?

Also how tight is too tight for new u-joints? I installed two new u-joints and one moves pretty freely, but the other is pretty tight but smooth.

 

common problem,did you note if the nut is pessed in one part?
if the seal is ok maybe oil is leaking between the threads.

 

The nut is still staked. I was going to replace the seal, but I was unable to get the nut to budge. The pinion just kept spinning. For now it is sealed with RTV, but I would like to replace the seal and nut eventually. How you you prevent leaking around the threads?

 

when I tightened my flange on my t-case, I locked my front hubs put it in 4hi, put it in 5th gear blocked the wheels and had at it. You have to unstake the nut first though.

 

dont use silicone on the threads,use this loctite product or similar.

Loctite 5770 Thread Sealant
High Temp Coarse Threads