I had my the rear tranny seal and all transfer seals replaced on my 2002 GV Manual about 2 years ago.  The transfer started to leak again about a year ago.  Does anyone else have this problem?  Are bearings problematic on these transfers, causing premature seal wear?

I have been very diligent with all fluid changes on this vehicle since new.

Thanks, Marc

I own two 2002 Trackers with the M59 five speed manual and 2 liter engines.  One now has 92K on it and the other 115K and no out put seal leaks on either one to date.  I owned a 2000 with a 2 liter and auto tranny and had 115K on it when I sold it with no leaks either.  Based on my limited experience with these three, that doesn't sound normal.

my input and output seals pretty much blew up at around 65k

I live in Edmonton.  Is it cold weather that blows out the seals?

The Suzuki manual says the transfer comes off without removing the tranny.  Anyone here done that?  Is this an easy repair?

I have done major work like this in front wheel and all wheel drive cars, but not in a north-south truck type layout.  I likely have everything I need except a tranny jack.

Thanks, Marc

I haven't pulled a transfer case out of a truck without dropping the whole tranny.  The manual I have shows separating a tranfser case off a dismounted tranny.  Suppose it's doable but it would have to be a major PITA.  Even with a body lift.   I'd ask a guy like Sean from AFTERMARKET4X4.  I'm guessing he does it from pulled trannys but if it has been done, I'm thinking he's probably one of the guys who has done it and tell you if it's worth the aggravation.

not sure what the cause is.  potentially a shitload of muddy and dirty roads and things getting dirty and not being cleaned up enough lettting the seals become damaged over time.  that is simply my guess.