So I'm in the process of replacing my rear main seal and swapping in an '04 transfer case on my '03. Planned on replacing all the input and output seals on the trans and transfer case while it's apart. Found that the transmission tailshaft is worn (a groove) where the transfer case input seal sits. Anyone else had this issue?


Looked like there was a slight leak from this area on the old transfer case. Figure I'm probably just going to have to roll the dice and see how it does with just a new seal installed in the interest of time (it's been apart for a month for head gaskets, oil pump, etc, and I need it back up and running)


Aside from replacing/overhauling the trans, my only thoughts were a seal saver repair sleeve (mixed reviews on the success of this) or trying to take 1/16"- 1/8" off the back of the seal so it sits deeper in it's bore and rides on an unworn part of the shaft..