Final drive leak D4D 49J

Had a final leak on a D8H years back, turned out to be O-rings on the aluminum part that the duo cone rubber ring seats against, always replaced them after that when we had a final apart.

Make sure the surfaces that the rubber ring on the Duo cone seal rides is free of dirt ,wire brush or sand surfaces on final drive case side and sprocket side .Check surface for a crack in final drive case . If you have the alumiun cages that was mentioned earler check for a crack in the cage ,and slways install new O rings behind the cage .
The tool shown only compresses the rubber ring to install it in the groove .same thing can be done by evenly working the rubber ring in the groove with your fingers .A little liquid soap on the rubber O ring makes it easer to seat the O ring in the groove so that It doesn't twist

The sprocket can be warn where the duo cone seal fits in, causing the seal to come out slightly and leak or even pinch the duo cone seal when assembled . I've been fighting this on my d8K 76V for about two months now. If you have the correct tooling it can still leak in this case.

Check distance between sprocket face and spline shoulder.
Dimension "A" should be 0.06 to 0.18 in.

rjh-md, has posted up some sound advice mooz, you dont need any fancy installer on the duo-cone seals, what tonnage are you pressing the rim on to and are you adjusting things up correctly, plus as O.M. has already posted the installing depth is important, D8H/K hubs do not have the alloy seal ring seatfitted, but often the lip gets worn out that retains the seal in place on build up, this can easily be sorted with a hammer in no time.
tctractors

thanks all for the help.

tctractors, we pressed about 25metric tonnes and followed manual as best.

Bugger, but will disassemble and try again.

while installing the the bearing cup into the cage assembly p/n 9k6842
described in 6k4665 Final Drive Group, managed to damage the aluminum rim seal insert that the outer duo cone seal set abuts on-best description is that is about 5/8" wide, angle rim that inserts into the end of the cage assembly.

Now the local cat dealer Hastings Deering suggests the p/n is a Retainer p/n 4k212? Available ex USA for $142 + post $12, non refundable if wrong.

Got an aftermarket P/n 4k212, turns out to be the aluminum cages for the inner duo cone seal set.

Also, Cat dealer sent me a set of d/c seals that I returned. So having no luck at all.

while installing the the bearing cup into the cage assembly p/n 9k6842
described in 6k4665 Final Drive Group, managed to damage the aluminum rim seal insert that the outer duo cone seal set abuts on-best description is that is about 5/8" wide, angle rim that inserts into the end of the cage assembly.

I looked up the seals in the 82J (equivalent to the 49J) for the same 6K4665 final drive group and the seal group is a 4K6049 (4 required per side). Does not show a part number for just the seat ring.

Regal shows the 4K6049 as a good number at $23.88 ea. so other after market sources ought to have them as well.