I recently explored the cause of my leaky front flange seal from the transfer case and despite my efforts have been unable to stop the leak. After dropping the front shaft and removing the nut the holds the front flange in place, I was surprised to find no washer or flange seal but some torn up little washer (attached). Easy fix I thought. I replaced the seal and washer but it’s no better. This is an early FJ60 transfer case on my pig and while 4WD works fine, the leak persists. I was surprised to find the washer is metallic and doesn’t have any sealing properties. When I tighten the nut too much, it’s hard to rotate the flange as the seal must compress and I’m worried it will get torn up when 4WD engaged. Would appreciate any insights.
