Engine/Transmission (1998.5 - 2002) Transfer case seal

[DNunemacher]

I am almost out of warranty 3yr/36000, I had this seal replaced in january 2003, it is leaking again. would this be covered if I go over the mileage? They blamed towing for the problem the last time. I asked them why would you sell a truck with a tow package, limited slip rear, 4. 10 rear and a diesel that you can't tow with? I am still waiting for an answer on that one! Is this one of those never ending unfixable dodge problems? Thanks Dwight

 

[KatDiesel]

Which seal?



If its the rear seal, alot of times its the vent on top of the housing.

 

[John]

DNunemacher, whoever told you that is seriously full of it!



IMO, the transfer case output shaft seal does not work all that well... they never have! By that I mean, I have had two NP208s and this NV241HD (same company... New Process, now New Venture Gear)... among other transfer cases I've owned The output shaft seals on the aforementioned transfer cases have habitually leaked ATF. I just installed my 4th output shaft seal on my NV241HD a few weeks ago. Although I haven't run the truck yet, I'm reasonably certain it will start leaking again within weeks of being back on the road.



And BTW, I'm not doing anything wrong in regards to installing them.



YES, I carefully remove the old seal

YES, I cleanup any foreign material in and around the seal bore

YES, I check for any imperfections on the slip yoke and seal bore and make corrections in a very anal way

Yes, I lubricate the seal lips with high quality synthetic grease

YES, I apply a light coat of silicone around the seal periphery to ensure of no leaks or weeps

YES, I align the seal weep hole at the 6 o'clock position (for drainage of ATF that got past the two seal wipers)... he!!, I even installed it once orienting the drain hole at the 12 o'clock position just to see if it would make a difference... ... nope! still leaked

YES, I apply a vey light coating of synthetic grease to the slip yoke

and YES, I very accurately guide the slip yoke onto to output shaft, easing it carefully past the seal



Yup, I been there many times before!



PS: I've never had any breathing restriction with either of these two models of transfer cases.

 

[DNunemacher]

vent

Kat Diesel, does this vent get blocked and need to be cleaned and after cleaning it will the leak stop ?

 

[kess]

DNunemacher

I have just been through the transfer case leaking from the rubber plug that is on top of the tail shaft housing of the 241HD. Mine leaked, I believe, because of the blocked vent tube. When I would remove the rubber plug I could actually hear a vacuum being released. I traced the line up to the engine compartment and removed the head of the vent line and blew some material out of the vent head. Since this (just last Friday), I have not experienced any leaks. I hope all of this makes some sort of sense.

Later,

Kess

 

[John]

Kess, Please keep us updated as to the longevity of the "fix. "



It might just be time for me to re-check the breather hose for blockage again.