Tcase leaks driving me nuts

[DaveB]

On my Commando I put a 241D transfer case behind a 700R4. The 241 has Dodge output shafts and a chevy input shaft. When I built it up I put in all new seals. The 700R4 doesn't have an output seal so the input seal to the 241 has to keep tranny fluid from getting into the tcase. Well it isn't doing the job and I keep losing tranny fluid and gaining tcase fluid. Maybe the new seal has problems so I will have to pull it apart and see what is going on. The other obnoxious leak comes out of the front output shaft. I used a chevy yoke on the dodge case and I keep getting leaks, not on the output seal but from the spline shaft. I have a new rubber gasket under the yoke nut and have even siliconed the washer and splines. It usually works for a while then starts leaking. The tcase is clocked and maybe the extra fluid from the tranny is causing too much pressure but I have never had so much trouble with a leaky yoke.
Any suggestions ?

 

[SLC97SR5]

Are the vents/breathers free of junk?

 

[bryson]

If I'm not mistaken, the splines on the t-case input are in a blind hole, right? If so, the splines don't go all the way through the input gear - so unless you are transferring oil into the t-case through the input seal, it has to be coming in another way...

Are your breather lines connected (T'd together?) Is it possible that the tranny fluid is getting into the t-case through the breather?

 

[DaveB]

I don't think I tied the vents together, I did make them long so that water can't get in them unless I go really deep. I figure there must be an issue with the tcase input seal since the input spline shaft is a blind hole. I'll look to see if the vents are clear of stuff and verify where the leaks are. Everything was nice and dry every time I checked it on our last Moab trip but I now have a puddle under it after the trip home.