The seal at the spud shaft is letting a lot of fluid by. I've tried a search on this site and google to find an online manual or instructional with no luck. Anyone have a link or insight on how to replace the seal? The box doesn't leak anywhere else.

Without going out and measuring the shaft, I don't know if this is the early or later version... Does this make a difference with the seal anyway (do they have a different shaft diameter where it comes out of the seal or just a different spline diameter?)? I think it might be the earlier larger version.

I've been able to get the large (around 3 or so inches) six sided threaded retainer off. Now what?

Also, I had NAPA order in a supposed reseal kit, part number #7-181. Does this ring a bell for anyone?

Any help/advice would be appreciated!

Factory service manual is more than enough to rebuild one. The seal kits does depend on which size input you have.

If you don't have to take it all the way apart don't -- you'll probably hate yourself if you have to rebuild the whole thing.

Better get you a service manual.:p

Unless you love torture, DO NOT do anything else. There is a series of teflon O-rings on the valve assembly and an O-ring that seals the valve assembly from the worm gear. If you don't know anything about the box, might as well get the rebuild manual and take it all the way down.

That little rubber piece your seeing that's 'letting a lot of fluid by' is just a dust cover. There is a large O-ring that does the actual sealing.

Where's the best place to pick up one of those manuals?

Service manual:
http://www.binderbooks.com/

I think Mechanos(?) did a pretty good write up awhile ago, I remember something about his rebuild kit had the wrong seal in it and he had to but 2 different kits to get what he needed.

This helped when I did it.
http://www.binderplanet.com/forums/showthread.php?t=73204&page=25
Starts on post 243.

Service manual:
http://www.binderbooks.com/

I think Mechanos(?) did a pretty good write up awhile ago, I remember something about his rebuild kit had the wrong seal in it and he had to but 2 different kits to get what he needed.

Didn't really do a write up on how to rebuild... was more on porting, but I did rebuild the box as part of the porting. Here's the link to my experience with Powercraft rebuild kits: http://www.pirate4x4.com/forum/showpost.php?p=1345569&postcount=20

also see post 22 in that same thread

Didn't really do a write up on how to rebuild... was more on porting, but I did rebuild the box as part of the porting. Here's the link to my experience with Powercraft rebuild kits: http://www.pirate4x4.com/forum/showpost.php?p=1345569&postcount=20

also see post 22 in that same thread

Yup, that's the one I was thinking of :beer:

Yup, that's the one I was thinking of :beer:

there are also some good links that people posted up for me when i did my drill/tap for hydro assist. check my build,there somewhere toward the end