Replacing T Case Seals

[RSchwarzli]

I have my transfer case out on a bench now as it has been belching out liquid the last little while. My question is how hard is it to replace the seals? Are there any special tools needed? Is this something that can be done at home?



Also, is there anything else I should be looking into while the case is opened. The t-case has 170K miles on it if that helps. Thanks



Robert

 

[Philip]

You can do it at home.



The seal for the front drive shaft yoke is NAPA #18752. The gasket under the seal mounting block is just a flat gasket. You can fab one from flat sheet gasket material.



The seal for the rear drive shaft yoke is NAPA#21213. Same thing on the gasket for the mounting block. Just flat sheet gasket material.



The seals for the splined connector shaft between the tranfer case and the trans are Dodge # 0416917 you need two of them by the Dodge parts break down. If you need the number for the connector I have it also.



I also have the numbers for all the rubber mounts used on the rear mount assy.



The other gaskets are flat sheet gasket material. Remove all the cover plates and look the bearings over for scouring/pitting/roughness. If everything looks good. Throw it back together and enjoy.



Look the seal surfaces over real good on the yokes. If they are groved where the seal runs. Move the position of the seal to get it into another place or speedy sleeve it or replace the yoke.

 

[WJune]

Grease the heck out of the sleeve that conects 205 to the trans. Both my 90 w350's were dry with red powdery rust on the splines. The first one ruined splines on 205, I caught the 2nd one in time as I pulled trans for repair.

 

[bgilbert]

Philip, did you and Jeremy go through his 205? I remember it had a healthy leak.



Link to some pics in a thread of my front output 205 leak: https://www.turbodieselregister.com/forums/showthread.php?t=81305

 

[Philip]

Jeremy's was a easy one. It was a rear drive shaft seal and yoke. His yoke was groved real bad. So he came over and raided my garage for the seal and yoke.



I had a new yoke and seal for my truck.

 

[RSchwarzli]

Thanks guys, I will be pulling it apart this weekend.

 

[TKingsbury]

I think I was looking at Quad4x4s site when I read that the gaskets need to be a certain thickness or they will affect bearing preload. You might want to look into it.

Travis. .

 

[DieselBuzz]

Philip

Could you post the numbers for the rear rubber mounts that attach to the cross member. (Mine are about the constancy of pudding)

Thanks

 

[Philip]

Travis the gaskets used in the 205's are thin. A standard gasket paper will not affect it enough to worry about. after it you compress it. It will come in real close to the orginal.



Something to think about. NAPA didn't list gaskets for a 205. If they were that critical it would they have been listed.



DB I'll get those number rounded up for you some time this weekend.

 

[TKingsbury]

I think the hot ticket would be to check clearances and such anyway (not that any of us would just jam it back together and hope for the best ). Since it's on the bench it should be pretty easy to get everything spot-on.

Travis. .

 

[Philip]

DB here are the numbers for the rubber mounts.



3820921 insulatoreng $11. 50ea

4106710 insul PKGW/SPA $17. 95 ea

152352 nut hex $5. 10 ea



You need 2 of all items.



The bolts are N/A. But they are listed as a 5/8's X 3 course thread. So these you can pick up at any truck supply shop or some parts stores.



The steel sleeve is not listed as a replacement part. So hope yours is good.



The nuts are lock nuts. Dodge supplies the good pinch type locknuts. Not the trashy nylon insert type nuts. The price is a little high from Dodge. But I don't reuse lock nuts.



Those prices were good as of last month when I picked the parts up. My mounts are like yours. Plus one of my upper mounts is gone.

 

[RSchwarzli]

Quote "The seals for the splined connector shaft between the tranfer case and the trans are Dodge # 0416917 you need two of them by the Dodge parts break down. If you need the number for the connector I have it also. "



Hey Philip, what is this conector? I am not versed on this part.



You wouldn't by chance have those numbers to the conector. My NAPA store says they are not available, and if they are I will need to find the number (I thought that was their job, guess not!). Thanks



Robert

 

[Philip]

I'll get the connector number tomorrow and price. My trans and transfercase are swaping oil. So I bought a new connector shaft just in case mine is groved where the seals ride.



This shaft is about 6" long and is splined on internaly one end for the trans output shaft and the other end is splined for the 205 input shaft.

 

[Philip]

Dodge calls the connector a sleeve. #4167920. List is $85. 75. This is for a auto trans.



The stick shift is a different splined sleeve. So the number would be different.

 

[RSchwarzli]

That is what i needed. Thanks so much.

 

[Moab4x4]

205 to 518 sleeve dry?

Grease the heck out of the sleeve that conects 205 to the trans. Both my 90 w350's were dry with red powdery rust on the splines. The first one ruined splines on 205, I caught the 2nd one in time as I pulled trans for repair.

So does this mean that all the ATF that ran out of the joint when I took off the transfer case means that my transmission is leaking at the rear? Inside the tail of the transmission where the sleeve is is all is clean and fully lubed with ATF.

 

[DVolk]

205 T case re seal

There is no big issues just use permatex on the paper/cork gaskets ,

but from exsperience buy ware sleeves ,or otherwise known as speedy repair sleeeves for the yokes ,i also recomend buying u bolt style yokes

the back one needs to be macjined to fit u bolts ,but its well worth it ,but you can order them from offroad design in colorado



does any one know of a mount for a twin stick t -case shifter setup ???

 

[RSchwarzli]

What part of the setup are you looking for info on. I ask as I am working on it currently

Robert

 

[DVolk]

replacing t-case seals

If your asking me which parts im looking for ,i need the shifter and mounts and if you got them the shifting rails for a 2 stick ,unless you got a set up to remove the crappy gated shifter set up ,but reguardless my rails need to be replaced ,im not getting 4 low in the case

 

[RSchwarzli]

My Bad, I was refering to your question on how to do it. The 93 t case bracket I have has two mounts. One for the auto and one for the stick transfer case trans setups. If wanting it configured for a separate 4wd, get an extra handle/ stick setup and use the same bracket. Install the new handle into the unused spot.



Robert