Dana 20 Oil Seal Question

I decided to go through a Dana 20 transfer case(new gaskets and seals) before I install it in my jeep.

I bought a Rugged Ridge kit. I took off the front output yoke, removed the old seal, felt, and gasket. I cleaned the gasket(a ring gasket that sits against a shoulder that was still in good shape), and the felt, to re-use.

The new seal is a double seal( 1/2" thick)vs. the single seal( 1/4" thick) that was in there. There appears to be plenty of room to accept the thicker seal. I installed it just slightly below flush with the yoke collar mounting surface. The original seal was in a little farther ( about 1/4" more).

The yoke slipped back on nicely, no apparent problems. As I started to torque the yoke nut to 240 ft. lbs., at about 20 or 25 ft. lbs., the yoke became very firm to turn( by hand). So I stopped.

What's going on here? Should I take the yoke off and set the seal in farther? Any other suggestions? Thanks for reading all this.

 

Sounds like the shield is hitting the seal. Drive the seal down against the shoulder and try again.

 

That could be it. So, when I go to drive the seal in further, should I send it in until it stops? There is that felt donut between the seal and the shoulder. Should I have left that out, or can the seal press hard against it? Thanks.

 

I always run the seal down to the bottom of the bore unless I need to position the seal to avoid a groove on the yoke seal surface. I don't use the felt seals although some do. To me it's a hold over from the days of leather seals to keep the seals from drying out. Make sure the yoke dust shield has not damaged the seal....

 

Thanks, Nickmil. You were right. The yoke flange was rubbing against the seal. I pressed the seal in 3/16" from the outer surface, and it worked out fine.