Pentair Challenger casing seal help

[Turkish]

I have just replaced my motor, seals, impeller, seal plate. Even chased the threads on the band clamp. I didn’t replace the seal plate o-ring but it’s pretty new. There’s a terribly bad leak along the mating surface of the seal plate. I can see water coming out at each gap in the band clamp, so it is obviously not even close to tight, although I can’t tighten it further by hand. Seems it’s much more than just an old o-ring.

I’ve fought this in the past and ultimately was able to get it tolerable, but it was never this bad. Are there common issues others have run into with these things? I went ahead and ordered a new front housing as well, thinking maybe it’s just gotten old, but I think I’m just doing something wrong. Any war stories to share?

 

[PoolStored]

I would replace the o-ring when you replace the front housing. Lubricate the new o-ring with silicone lubricant (like magic lube II). Don't use PTFE/Teflon lube.
You may also have some issue with the old band clamp.
o-rings are cheap, anytime you dig through a motor, replace all of them.