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Archived Transfer case breaking bolts AGAIN

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Archived Help!!!!!

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My truck is down again! 92 W350 with A/A NV4500 kit and it's leaking between the transfer case and trans adapter. This is the third time. Today while driving from central Ohio to Eastern panhandle of West Virginia, I found it starting to drip. I was about 100 miles out and turned around because I have tools and a better place to work in Ohio. What I can't figure out is what is causing the bolts holding the NP205 to the transmission adapter breaking and leaking. Does anyone have any idea?



Mark
 
Is the adapter carrying the weight of the t-case? If you have a crossmember supporting the t-case, is the mount in good shape? What about the transmission mount?
 
Yes the adapter has to support the whole T/case weight. The cross member and rubbers mounts (new when trans was replaced) are on the transmission extension housing. It looks like it's designed that way. Does any other 1st Gen 4x4 5 speeds have support on the transfer case?



I got the truck with bad 4th gear, drove a bit going from 3rd to 5th and the trans extension housing broke, ended up locking the transmission. Replaced it and I messed up using normal blue permatex, it started leaking on the first 400 mile trip. I tore it apart and used the black high temp, added fast coolers and I had no problems for about 1000 miles, one trip 400 miles with truck and trailer 14K gross. It started leaking on the return trip with empty trailer. I plan to have both drive shafts balanced as it seems to vibrate a bit more than I think it should.
 
I'm not sure how the t-case was supported with the factory Getrag installation, but I'd bet that it not being supported is part, if not all, of the problem. I helped R&R me4osu's t-case a couple of weeks ago & I can tell you that puppy is HEAVY!



I would strongly recommend that you put a crossmember & mount at the balance point of the case. If you don't have the equipment to fabricate one, perhaps there's a 4x4 shop near you that can help.
 
Yes I agree it's HEAVY! I have had it out two times. I also plan to check under a friends 89 W350 to see how his is supported.



The first time out only 3 of the 8 bolts were broke and that was all I replaced, the second time 2 were broke (1 old 1 new) so I replaced all 8. They were grade 5 3/8x1 1/4 bolts. I am thinking of going to grade 8 bolts for the third go around.



I wonder if a dealer could tell me what the factory had? Because it had grade 5 when I first got into into it I thought they were stock.
 
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