transfer case leak

[fordsohc46]

i have a 78 bronco with a np205 transfer case. it has a leak at the rear shaft yoke seal. i have replace the seal 3 times and filled the grooves from the old seal on the yoke with metal filler but it still leaks. i have fixed axles with seal grooves before with metal filler and stopped the leak but it is not seeming to work on this yoke. i was wandering if there should be a oil slinger behind the seal on this transfer case b/c mine hasn't got one and when i pull the seal there is alot of oil that comes out like maybe too much for the seal to hold in. if it isnt supposed to have a oil slinger i guess i can try a new yoke from jeffs bronco graveyard. any input would be appreciated.

 

[fordsohc46]

ordered new yoke and seal from jbg. hope this fixes it. i have found diagrams on internet none show oil slinger but some show a metal washer and a rubber washer behind nut neither of which my bronco has. anyone have any ideas on this?

 

[Broncobill78]

It's been a really long time since I took a 205 apart but I do seem to remember those parts. If Jeff's has them it probably wouldn't be a bad idea to replace them now but if taking it apart isn't a big deal for you then try it out with the pieces you have coming & see how it does, obviously if it still leaks then you'll know they're necessary but it may well do fine without them. Let us know which way you go with it and how it works out. I'm curious because I just picked up another 79' and I'll probably freshen up the transfer case over the summer and knowing if those parts are important & available would be useful info.

 

[fordsohc46]

i put the new yoke and seal in yesterday drove it home and it still leaks. it is coming out from around the yoke where the seal should seal it. i have found a seal kit from jbg below is the link part #21638. i m not sure if this will fix my problem though because it is not coming from the splines of threads of the yoke but around the yoke where the seal should be sealing. it seems like too much oil is getting up to the yoke bc when i pull the yoke with the seal still in there a steady stream of fluid runs out. im not sure what to try next. the only other explanation would be that my rear gears are worn out. i put new bearings in rear but didnt have money to replace gears so i am running old gears with bad wear pattern but i dont have a vibration but it does howl very badly between 45-50mph. but i dont think this could cause my transfer case seal to leak. it might should cause my rear pinion seal to leak but it is fine.

http://broncograveyard.com/bronco/i-21638_..._gasket_kit.htm

 

[Broncobill78]

Hmmmm, at this point the only thing I can honestly think of to suggest is that the problem is with the output shaft itself. Jeff's doesn't list one in their catalog but may well be able to get you one or any other Spicer parts dealer should be able to as well. Advanced Adapters has a heavy duty alloy shaft available as well.

http://advanceadapters.com/product/4111/(P...tput-shaft.html

I don't know what the pricing is for a new shaft but it's probably not that much more for the HD shaft (but that's just a guess, I really have no idea. If you look into it & find the info please post it). However, you can replace the entire case for less than the cost of the A.A. HD shaft. At this point I'd probably elect to bite the bullet and replace the Xfer case with something from Jeff's and be done with it. I'm sure they'll guarantee you one that's in reasonable shape & won't leak. Depending on what kind of 4-wheeling you do you could just leave it at that or take your time & rebuild the leaking box at your convenience & then swap it back in later when it's done.

http://broncograveyard.com/bronco/i-21602_...ansfer_case.htm

By the time you chase down the problem then find & buy the rebuild parts you'll probably have spent a lot more time & about the same cash as it would run you to just change the case. Thanx for the update, it's nice to find & it's informative to know how people make out with problems like this. Let us know what you wind up doing or how you make out.

 

[fordsohc46]

i think i fixed my leak. i pulled the yoke back out and removed the seal retainer. there was a gasket and lots of silicone behind seal retainer housing. on the bottom of housing on the inside there is a valley for the oil pumped up to **** rear bearing to drain back down. this valley was full of silicone from the last time that gasket was replaced and was causing oil build up in this housing and it had nowere to go but puke out the seal around the yoke i drove it 85miles last 2-3 days and still no leak. usually it would leak within 10-15 miles depending on driving conditions so i believed i fixed the problem

thanks for the posts!

 

[Yardape]

i think i fixed my leak. i pulled the yoke back out and removed the seal retainer. there was a gasket and lots of silicone behind seal retainer housing. on the bottom of housing on the inside there is a valley for the oil pumped up to **** rear bearing to drain back down. this valley was full of silicone from the last time that gasket was replaced and was causing oil build up in this housing and it had nowere to go but puke out the seal around the yoke i drove it 85miles last 2-3 days and still no leak. usually it would leak within 10-15 miles depending on driving conditions so i believed i fixed the problem
thanks for the posts!

Maybe the tcase is empty? Lol, congrats.