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Old 06-12-2010, 06:08 AM   #1 (permalink)
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Default Transfer case front seal leaking again…

Greetings...

I noticed the front seal on the transfer case leaking some time around the 45K mark. The cross member was saturated as was the front section of the case. Accoring to my records the dealer replaced the seal under warranty on 3/17/10 @ 45,723 miles. I changed the oil @ 46,467 and noticed the area was clean and no further leaks. As a precaution I steamed cleaned the undercarriage to check for any new leaks. Due to some work related travel I accumulated significant mileage and recently replaced the oil @ 54,803. To my surprise and disappointment the front transfer case seal has begun leaking since the last oil change. The cross member is saturated again…

I’ll make another appointment with the dealer so they can repair it again!

Has anyone experienced any transfer case leaks? If so did the leak come back after the repair?

Either the seal was faulty, the repair was improperly performed or the transfer case output shaft may be defective causing premature seal failure. I doubt the shaft is faulty as the intial leak would have occurred sooner than the 46K.

Your input/experience is appreciated.
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Old 06-12-2010, 09:57 PM   #2 (permalink)
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No such leak here, but we're only at 30,000 miles.
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Old 06-13-2010, 03:03 AM   #3 (permalink)
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VERY COMMON leak. I've replaced at least 100 of those seals I think..it sucks.

It is Suzuki's problem, whether they admit it or not. I've seen those seals leak at 2000km before, that's right - before the first oil change! Don't blame the mechanic that installed the seal - it's not their fault.

Suzuki knows about the problem from what I've been told but I doubt they will come out with a fix for it. I've been waiting two years to see it happen.

In my opinion the seal is mounted too far forward in the case, and the shaft is too short. The seal rides on the very edge of a taper on the shaft - and there is enough up and down movement in the shaft to allow leakage. The seal needs to be installed like 1/16" of an inch further in - which wouldn't be hard to do with a proper spacer put in first, and then the seal. I haven't tried this because warranty jobs must be done according to original. That's just my opinion why they leak too. I took some pictures once - I'll try and find them.

So, have it replaced again but expect it to leak down the road. Sometimes they'll go a long time before they leak - other times it happens again within the year.
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Old 06-13-2010, 05:23 AM   #4 (permalink)
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Quote:
Originally Posted by Jeff L. View Post
VERY COMMON leak. I've replaced at least 100 of those seals I think..it sucks.

It is Suzuki's problem, whether they admit it or not. I've seen those seals leak at 2000km before, that's right - before the first oil change! Don't blame the mechanic that installed the seal - it's not their fault.

Suzuki knows about the problem from what I've been told but I doubt they will come out with a fix for it. I've been waiting two years to see it happen.

In my opinion the seal is mounted too far forward in the case, and the shaft is too short. The seal rides on the very edge of a taper on the shaft - and there is enough up and down movement in the shaft to allow leakage. The seal needs to be installed like 1/16" of an inch further in - which wouldn't be hard to do with a proper spacer put in first, and then the seal. I haven't tried this because warranty jobs must be done according to original. That's just my opinion why they leak too. I took some pictures once - I'll try and find them.

So, have it replaced again but expect it to leak down the road. Sometimes they'll go a long time before they leak - other times it happens again within the year.
Thanks Jeff...

I was hoping I wouldn't see a response like yours, but it is what it is. Fortunately for me the warranty in the US is 100K on the powertain. Considering my useage, I probably have less than years left. I'll go back and have them replace it. Although I don't care to see it leak again, I hope the leak comes back very soon then I can implement the "Lemon law" issue and see what happens from there...

Once agasin, thanks for the input!

Cheers!
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Old 06-13-2010, 08:49 AM   #5 (permalink)
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Yes, mine started to leak at 40,000 km, it has been replaced. Now I'm at 57,000km and it looks like it started to leak again.
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Old 06-13-2010, 10:29 AM   #6 (permalink)
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My '06 GV didn't have this problem (100,000km)

But on my '09 GV the seal has recently been replaced at 55,000km
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Old 06-13-2010, 12:57 PM   #7 (permalink)
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i've noticed the same leak around my t-case front seal as well, my GV only has 15,000km, i am keeping a close eye on it,
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Old 06-15-2010, 07:38 AM   #8 (permalink)
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Default oil leak

Hi there, i have a 2009 2.4l petrol with only 3000 miles on the clock with the same leak, its in the dealers at the moment waiting for parts to come. My dealer says Suzuki are aware of the problem and there is a modified part, seal with a circlip. i will try and find out more information when i collect the car, hopefully sometime tomorrow. regards paul.
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Old 06-15-2010, 08:18 AM   #9 (permalink)
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Quote:
Originally Posted by williamthorpe271 View Post
Hi there, i have a 2009 2.4l petrol with only 3000 miles on the clock with the same leak, its in the dealers at the moment waiting for parts to come. My dealer says Suzuki are aware of the problem and there is a modified part, seal with a circlip. i will try and find out more information when i collect the car, hopefully sometime tomorrow. regards paul.
I'd be interested to know, however I think you are having a different seal replaced. Probably the output seal for the front drive shaft. Those were very common failures in the early run of the 2009 GVs. There is a circlip that holds the shaft yoke in the t-case.
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Old 06-15-2010, 08:36 AM   #10 (permalink)
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Default leak

Hi Jeff L, i have hopefully attached a picture so you can see oil leak. regards paul.
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Transfer case front seal leaking again…-dsc00154-small-.jpg  
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