NP205 Leak

[AKimmel]

I have an 89 W350 gas burner that I can't get the rear output seal to stop leaking on. I've replaced the output shaft, bearing, yoke, and seal. I've tried different seals with no luck. I originally thought it was my driveshaft vibration causing it to leak, which I just had rebalanced by a different shop for the second time. I discovered it's not the driveshaft causing it, because I ran the truck up to speed sitting in the shop with no shaft at all, just the yoke, and I could watch gear oil to start flowing out between the yoke and seal. I've check the T-case vent also, and it is clear. One thing I am suspicous of, is there is not a drain hole for the oil that collects behind the seal to drain back in the case. If you look at the aluminum seal retainer, there is a drain cast into it along with a notch in the gasket, but my bearing retainer housing doesn't have a hole for the drain to match up to. I've emailed Quad4x4, and he said most 205 don't have a drain, but some do. I want to drill a drain hole, but don't know the correct size and neither did Dan at Quad4x4. Anyone out there have a case apart with a drain hole they can measure for me, or at least a picture of the factory drain hole? I think they put drains in the later cases that were made. My 87 service manual doesn't mention a drain, but my 90 and 93 manual both have a note to line up drain hole. I think oil is building up there faster than it can drain back into the case through the bearing and forcing it out past the seal. Someone please help me out, I'm tired of throwing money at this thing. Thanks, Alex

 

[dpuckett]

If you're just wanting a place for oil to drain, any size hole should work- 1/8" or so would be what I'd do. Obviously, oil gets slung up there, and getting it drained back is only limited by keeping the drain bigger than the supply.



Daniel

 

[AKimmel]

I don't know if 1/8" would be big enough when the oil is cold, but I don't want to go too big either and not allow any oil to stay in there for the bearing. I found a picture of the front drain hole, and it looks to be 1/4". I think drilling a hole for the rear would solve my problem, but I wonder why they aren't drilled? I'm hoping someone has a 205 from a 93 laying around they can pop the seal retainer off and look at to see if it's drilled. The 93 would be the last one made, so I'm wondering if they are the ones that are drilled. I have a 205 out of a 71 Chevy, I checked it yesterday, and no hole. So it's not the early ones that are drilled. I will probably drill mine tomorrow, so I hope someone comes up with something confirming this before then.

 

[DVolk]

NP 205 Leak

Id try a speady sleave this will fit tighter on the yoke reguardless if its a new one or not then some seal sweller , I never heard or seen a drain before on any ive been into . Id call Dodge or depending on your area

call Six States Distributing They are a Dealer for New Process

or even possibly call Boyce Equipment in Ogden UT

 

[AKimmel]

I called Dodge that I deal with to see if the part number updated or if it listed with or without a drain. He said the part number for the bearing retainer did update, but they are all canceled parts and it doesn't give a description anymore. What's weird is it lists the bearing retainer the same up to 92, then 93 is another part number. I still think 93 might have a drain in it. I've talked to some drivetrain shops, and all have said that they have seen them with drains before, but nobody has been 100% sure of what size and what had them. The front has a drain, so I don't see why the rear can't? Plus, it still puzzles me why the seal retainer and gasket are both made with a drain, but there is no hole for them to drain into. This is the 3rd Dodge I've had with a 205 and have never had this problem before. I think it has something to do with the rpm's it turns because of the low gears.