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Unread 07-23-2013, 07:49 PM   #1
Why J?
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Bought a Tom Woods SYE and driveshaft back in 09 shorty after I got my first lift. The housing has leaked ever since. In fact the case also leaked and I have had an epidemic of it staying in 4 wheel drive.

I have had the thing out and apart at least 2 dozen times trying to seal it. I hate leaks!

image-3432708431.jpg

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Unread 07-23-2013, 08:00 PM   #2
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More rtv.
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Unread 07-23-2013, 08:06 PM   #3
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Quote:
Originally Posted by Anticanman
More rtv.
Look at the pic closer. The mode fork bushing is .20" larger than the hole in the tail shaft housing. Which results in the housing not sitting flush with the rear of the case causing a leak.

It also pulled the rest of the case out causing a leak between the 2 cases. With everything out of alignment it binds the shift mode fork keeping it in 4 WD.

It is eating the front input seal and bearing along with the output bearing and seal. Probably some excessive wear to the internal components as well

I have been fighting it for going on 5 years. Never crossed my mind that it didn't fit right I have been caking it with RTV.
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Unread 07-23-2013, 08:12 PM   #4
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Are you saying it is leaking from both housing halves, the main housing and the tail shaft housing? If so, make sure you are reassembling correctly and make sure that the mating surfaces are going together flush. The halves should all pretty much go together fairly tight without the torque of the assembly bolts...if you are having to "pull" the halves together with the bolts, then something isn't going together correctly. Also, make sure you don't have any gouges on the mating surfaces. The fact that you have had the halves apart so many times makes it entirely possible that there are a few nicks and gouges, which make sealing very difficult.

If everything checks out, then do as suggested above, and make sure you are using enough RTV. If you don't have a decent bead the entire circumference of the mating surface when you tighten down the bolts 1/2 turn, then you aren't applying enough RTV. One last suggestion, make sure you are following the directions on the RTV tube...
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Unread 07-23-2013, 08:19 PM   #5
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No no. What I am saying is that the hole in the sye tail housing for the shift mode fork is to small for the shift mode fork bushing. Resulting in what is pictured.

When the tail housing bolts are torqued down it causes the tail housing to leak. It also pulls the rear case out causing the case to leak. And binding everything up.

The mating surfaces are perfect. I had them checked by a machine shop and decked. They are the tightest fitting np231 case halves on earth. But that does nothing if the case gets torqued by the tail housing.
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Unread 07-23-2013, 08:26 PM   #6
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Quote:
Look at the pic closer. The mode fork bushing is .20" larger than the hole in the tail shaft housing. Which results in the housing not sitting flush with the rear of the case causing a leak.
I'm not familiar with the TW SYE set, but I have used the Rugged Ridge kits, so I am not sure if the following information will be of any benefit. I've never heard of the fork shift rod being too large OD, but I know some of the earlier model transfer cases have shift rods that are too long, and have to be cut down to work with SYE tail housings. I will also say this, every time I reassembled mine it looked a lot like yours pictured above. I must have watched the SYE assembly video on YouTube 2-3 times, and every time those guys assembled it the case just fell together. Mine took quite a bit of manipulation to get everything correctly lined up, and even took some careful taps around the housing case with a small dead blow hammer to get everything together flush. At times, I was convinced I had a problem, but it simply came down to me not assembling it back correctly.
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Unread 07-23-2013, 08:33 PM   #7
1946Flattie
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Measure the rod (or bushing, or whatever greets the ID of the housing's bore). Take the tail housing to the machine shop and ask them to open the hole to a slip-fit tolerance for that measurement. A quick drill/ream and you should be good to go. I'm a machinist and I'll tell you they can be in and out in a couple of minutes and your troubles should be over.
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Unread 07-23-2013, 08:37 PM   #8
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The fork rod isn't the issue. The rod fork bushing that is in the back of the case. See the pics

Case halves fit together fine. The tail housing is wrong and throws everything else out once its all torqued down.
image-1115538434.jpg

image-1194441893.jpg

image-24325018.jpg

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Unread 07-23-2013, 08:38 PM   #9
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I had to cut the shift rod as well. I can't remember how much I had to cut but you should be able to search and find the answer.
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Unread 07-23-2013, 08:40 PM   #10
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Quote:
Originally Posted by 1946Flattie
Measure the rod (or bushing, or whatever greets the ID of the housing's bore). Take the tail housing to the machine shop and ask them to open the hole to a slip-fit tolerance for that measurement. A quick drill/ream and you should be good to go. I'm a machinist and I'll tell you they can be in and out in a couple of minutes and your troubles should be over.
Yea it's easy to fix. We have a machine shop at work so Ill walk the tail housing down and have it opened up.

I was posting up in case someone else runs into this. With all the SYE kits out there I can't be the only one. It also pisses me off that I have replaced seals and bearing 3-4 times now along with an all new case and to have it decked. Never checked the tail housing for proper dry fit till tonight while getting ready for another complete rebuild of the case.
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Unread 07-23-2013, 08:41 PM   #11
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I don't mean to sound like a jerk, but 5 years of problems and dozens of removal and reassemblies? I would have trashed that a looong time ago and bought a new one.
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Unread 07-23-2013, 08:43 PM   #12
1946Flattie
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I see what you're saying, but still, opening up the hole in the tail housing should solve the issue. Most of the SYE kits on the market today have the machined components outsourced to China, even my JB Conversions super short was outsourced. We all know that the QC coming from there isn't always the best, so it's entirely possible that a component with an undersized bore could've left the factory. I believe if you have the hole opened to the proper size you'll be a-okay and the issue will be resolved.

Edit: missed your last post. I knew you were in some sort of manufacturing environment when I saw the Mitutoyos.
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Unread 07-23-2013, 08:44 PM   #13
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Quote:
Originally Posted by HKusp
I don't mean to sound like a jerk, but 5 years of problems and dozens of removal and reassemblies? I would have trashed that a looong time ago and bought a new one.
I have swapped cases twice and just last week bought a new case. Thought I was just fing up the RTV. I though I was just TCase retardted.
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Unread 07-23-2013, 08:48 PM   #14
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Quote:
The fork rod isn't the issue. The rod fork bushing that is in the back of the case. See the pics

Case halves fit together fine. The tail housing is wrong and throws everything else out once its all torqued down.

Yea it's easy to fix. We have a machine shop at work so Ill walk the tail housing down and have it opened up.

I was posting up in case someone else runs into this. With all the SYE kits out there I can't be the only one. It also pisses me off that I have replaced seals and bearing 3-4 times now along with an all new case and to have it decked.
Why didn't you simply post all this information and pics in the first post, it would have prevented a lot of confusion. The first post made it sound like you had no idea what was causing the leaks...
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Unread 07-23-2013, 08:48 PM   #15
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Quote:
Originally Posted by 1946Flattie
I see what you're saying, but still, opening up the hole in the tail housing should solve the issue. Most of the SYE kits on the market today have the machined components outsourced to China, even my JB Conversions super short was outsourced. We all know that the QC coming from there isn't always the best, so it's entirely possible that a component with an undersized bore could've left the factory. I believe if you have the hole opened to the proper size you'll be a-okay and the issue will be resolved.

Edit: missed your last post. I knew you were in some sort of manufacturing environment when I saw the Mitutoyos.
I'm a manufacturing engineer it is my job to catch crap like this. We deal with nm at work and this amount of being "out" is huge for me.

Apparently I can't do my job at home. Lol.
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