4.0 and Manual Transmission Rear Main Seal

[carpenle]

I found this on another forum but thought it was good info. I also had the same hole on the XJ, so it applies to them as well.

"Just so you guys know. There is a TSB (tech service bulletin) regarding the rear main seal.
It involves sealing the gap at the top of your bellhousing. this prevents dirt and debris from collecting around the seal and causing premature failure."

Engine - Apparent Rear Main Seal Oil Leaks


NUMBER: 09-010-04 REV. A

GROUP: Engine

DATE: October 01, 2004

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-010-04, DATED MARCH 16, 2004, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **********S** AND INCLUDE THE ADDITION OF THE 2005 MODEL YEAR.

SUBJECT:
4.0L Engine - Dirt And Debris Accumulation At Rear Main Seal

OVERVIEW:
This bulletin involves the application of a small amount of sealer where the top of the transmission bellhousing mates to the engine.

MODELS:

**1997 - 2005** (TJ) Wrangler
NOTE :**This bulletin applies to vehicles equipped with a 4.0L engine (sales code ERH) and a manual transmission (sales code DDQ, DDD, or DEH) that were built prior to September 02, 2004 (MDH 0902XX).**

SYMPTOM/CONDITION:

The customer may experience engine oil seepage from the area of the rear main bearing seal. Closer inspection may reveal that the cause of the engine oil seepage past the rear main bearing seal is due to the accumulation of dirt and debris around the outside of the rear main seal. This condition may occur more frequently if the vehicle is used in off road conditions.

A spacer plate is used to mate the transmission bellhousing to the back of the engine. The spacer plate has a slot machined into it at the 12 o'clock position. A small opening may occur as a result of the spacer slot when the spacer is mated between the engine and transmission bellhousing. The narrow spacer opening at the top of the transmission bellhousing may allow small size debris to enter the bellhousing and accumulate around the outside of the rear main engine seal. If debris accumulation becomes significant, damage to the rear main seal may occur.

DIAGNOSIS:

If a vehicle is in for service perform the Repair Procedure if the repair has not previously performed.

If engine oil seepage from the engine rear main oil seal is present, then diagnosis and repair not addressed by this Bulletin may be required.




PARTS REQUIRED:

REPAIR PROCEDURE:

1. With the ignition switch in the off position, raise the vehicle hood and make sure the engine and exhaust manifold are not hot to the touch

2. Locate the narrow opening created by the spacer plate. The spacer opening can be viewed when looking towards the rear of the engine and top of the transmission bellhousing from the drivers side of the engine (Fig. 2).

3. Thoroughly clean the immediate area around the spacer opening with throttle body cleaner, p/n 04897156AA. Allow cleaner to dry.

4. Apply a sufficient amount of RTV over the spacer opening. Verify that the spacer opening is completely sealed off by the RTV.

5. Lower and secure vehicle hood.

POLICY:
Reimbursable within the provisions of the warranty.