[Roadglide]

I have z force trail 800 2018 with 1300 miles it has gear oil leak at the cover motor assembly it appears to split with 8 mm hex . There are 2 harnesses going to the plastic case I'M assuming it's  front 4 wheel engaged . The question  is can that assembly be split and fix the gear oil leak ?

[NMKawierider]

I have z force trail 800 2018 with 1300 miles it has gear oil leak at the cover motor assembly it appears to split with 8 mm hex . There are 2 harnesses going to the plastic case I'M assuming it's  front 4 wheel engaged . The question  is can that assembly be split and fix the gear oil leak ?

The plastic piece in front with the wires going into it is the actuator assembly. That can be removed and replaced pretty easily. I have an interesting story about that as well. I too found gear oil coming from that front area and at first look, it appeared it was from loose bolts of that assembly so I tightened all of them...and two are not easy to get to. I also noticed where the wires went into the unit it looked like oil was also leaking there. I blasted that whole thing with brake parts cleaner and slapped some black RTV all around it and included the wires. Let it set a few days. Never saw any more leaks.

[Roadglide]

Thank you I'll be trying the cleaning and black silicone

[Roadglide]

I found the actuator or front axle differential had warped there was a split between the 2 parts where the actuator bolts up . The correct way would have been to remove it if I had know or could have seen the split.  I ground the skid plate front welds bent it back to see the split . I cleaned the back area filled it with black rtv  let set 4 days no oil leak . I hope it stops the leak because that rtv is hard rubber to remove.

[NMKawierider]

I found the actuator or front axle differential had warped there was a split between the 2 parts where the actuator bolts up . The correct way would have been to remove it if I had know or could have seen the split.  I ground the skid plate front welds bent it back to see the split . I cleaned the back area filled it with black rtv  let set 4 days no oil leak . I hope it stops the leak because that rtv is hard rubber to remove.

Good luck. Wonder why it cracked in the first place. Are all the mount bolts tight?

[Roadglide]

Yes there are 4  8 MM hex bolts securing the actuator is plastic with O  ring and bolted to the front differential . I'm thinking there should be no pressure on the actuator for shifting in and out  4x4 drive .

[NMKawierider]

Yes there are 4  8 MM hex bolts securing the actuator is plastic with O  ring and bolted to the front differential . I'm thinking there should be no pressure on the actuator for shifting in and out  4x4 drive .

Is t the actuator's plastic that's cracked or the diff case?

[Roadglide]

It appears one part is warped the axle face or actuator it's small uneven area where gear oil was leaking .

[NMKawierider]

It appears one part is warped the axle face or actuator it's small uneven area where gear oil was leaking .

Oh..

[Roadglide]

The reason it looked warped because the 0 ring slipped out of the grove when assembled . I removed the winch cleaned the silicone from the actuator removed 4 bolts the actuator came off easy and sprayed crc to clean . The o ring was pinched out of the grove. I used silicon black gasket maker  on the o ring and the face of the actuator to the front axle. Ill have a o ring here when I get back from quartzsite AZ.

[NMKawierider]

The reason it looked warped because the 0 ring slipped out of the grove when assembled . I removed the winch cleaned the silicone from the actuator removed 4 bolts the actuator came off easy and sprayed crc to clean . The o ring was pinched out of the grove. I used silicon black gasket maker  on the o ring and the face of the actuator to the front axle. Ill have a o ring here when I get back from quartzsite AZ.

Funny you should mention that O-ring at this time. I had been having a small oil leak from the lower side of the actuator-to case for a while and as I was down for the cold months, decided to take a look. Seemed the O-ring must have an issue so I ordered one from Alpha-Sports and prepared to replace it. Removed the actuator, cleaned everything up and saw that the O-ring between say 3:00 and 7:00 was flush with the case where the rest stuck out slightly above as expected. Pulled the old one, cleaned the grove and area and installed the new one. Still, it was just at the surface of the case as the old one was. Micrometer showed that area at it's deepest was over .008 deeper then the opposite side so I can only conclude it was cut off center. Cleaned it well with Brakeclean, filled the entire grove with black RTV, slipped-in the O-ring, put a nice bead on the actuator base and re-assembled. I'll let it sit a few days before re-filling it with oil but I am hopeful this fixes that leaking issue. 

[Roadglide]

The silicon sealed the actuator there has been no leaks running it hard in the desert for over 300 miles .

[NMKawierider]

The silicon sealed the actuator there has been no leaks running it hard in the desert for over 300 miles .

Great!