Transfer case is leaking, need help - JeepForum.com
Search  
Sign Up   Today's Posts
User: Pass: Remember?
Advertise Here
Jeep Home Jeep Forum Jeep Classifieds Jeep Registry JeepSpace Jeep Reviews Jeep Gallery Jeep Clubs Jeep Groups Jeep Videos Jeep Events Jeep Articles
Go Back JeepForum.com > Models > Jeep Wrangler Forums > TJ Wrangler Technical Forum > Transfer case is leaking, need help

Introducing MONSTALINER™ UV Permanent DIY Roll On Bed LineToxic Brakes - 3000 PSI Braided Stainless Steel Brake LineCess Recovery Gear Snatch Tow Strap OffRoad @ ROCKRIDGE4WD

Reply
Unread 05-20-2008, 04:52 AM   #1
Black06X
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ct
Posts: 140
Transfer case is leaking, need help

I have an NP231 under my X that I noticed started to leak pretty substantially this morning. The odd thing is, it doesn't seem to be cracked anywhere, it just seems to be leaking from the seem that splits the case in half. I did an SYE about a year ago, and I am wondering if i just didn't use enough RTV in one spot or something. I'm hoping that is the problem. Does anyone else have any clue as to what the problem might be? As I said, it doesn't look like it is cracked or anything like that, and none of the oil seals seem to be leaking at all. I suppose I am just going to split the case today and see if i can see anything wrong, and just be extra careful when I reseal it this time. Is there any problem that I might be overlooking that anyone else can think of?

__________________
2006 X, RE 4.5" SF lift (3.5" springs) AA SYE + Tom Woods CV shaft, SRC Front+Rear bumper+rock guards, Daystar 1" body lift, 32" X 11.50" BFG Muds on American Racing Teflon 15 X 8's, PIAA fogs, On the way: G2 dana 44's front/rear,Trutrac (rear) and ARB (front), OBA, rear disk brake conversion, BFG 35's
Black06X is offline   Reply With Quote
Unread 05-20-2008, 05:17 AM   #2
Black06X
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ct
Posts: 140
Well I think I found the problem.


The plug in the tail housing seems to be missing. I am not sure how that plug could've worked its way loose, but its not there anymore, so it must have. Its been so long since I have had this apart, so I had a question. What is actually in this hole? It almost looks like it bottoms out, but I stuck a mini flathead in there, and where I thought it looks like it bottoms out, there seems to be something that I can catch the screw driver on, and move around. It says in the write up, this kit is for an XJ also, and that is where a shift rail would be. What is in there on a TJ?
__________________
2006 X, RE 4.5" SF lift (3.5" springs) AA SYE + Tom Woods CV shaft, SRC Front+Rear bumper+rock guards, Daystar 1" body lift, 32" X 11.50" BFG Muds on American Racing Teflon 15 X 8's, PIAA fogs, On the way: G2 dana 44's front/rear,Trutrac (rear) and ARB (front), OBA, rear disk brake conversion, BFG 35's
Black06X is offline   Reply With Quote
Unread 05-20-2008, 05:36 AM   #3
abnormal
Platinum Member
 
abnormal's Avatar
1996 XJ Cherokee 
 
Join Date: May 2005
Location: Just around the corner...
Posts: 1,790
The shift rail is what you are pushing. For the tj I think the rail is shorter than an xj.
__________________
DURTYROK CAROLINA OFFROAD
abnormal is offline   Reply With Quote
Unread 05-20-2008, 05:45 AM   #4
Black06X
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ct
Posts: 140
Thats what I thought it might be, so on the TJ, the picture is correct, I am supposed to have that plug there? I hope thats all that is, I really don't want to have to take that thing apart again. I guess upon looking at it further, that has to be what the problem is. There isn't enough space between the shift rail and the housing to allow the aft to pour out, but there is enough to have a slow leak while driving. The atf is puddled on top of the skid which is why it appears to be leaking at a standstill as it drips from all the holes in the skid. Now the million dollar question, what thread size is that hole. I am at work right now, and can't seem to find anything that fits. I guess I should just call AA and ask them.
__________________
2006 X, RE 4.5" SF lift (3.5" springs) AA SYE + Tom Woods CV shaft, SRC Front+Rear bumper+rock guards, Daystar 1" body lift, 32" X 11.50" BFG Muds on American Racing Teflon 15 X 8's, PIAA fogs, On the way: G2 dana 44's front/rear,Trutrac (rear) and ARB (front), OBA, rear disk brake conversion, BFG 35's
Black06X is offline   Reply With Quote
Unread 05-20-2008, 06:03 AM   #5
abnormal
Platinum Member
 
abnormal's Avatar
1996 XJ Cherokee 
 
Join Date: May 2005
Location: Just around the corner...
Posts: 1,790
Yeah ask aa. They can sell you one.
__________________
DURTYROK CAROLINA OFFROAD
abnormal is offline   Reply With Quote
Unread 05-20-2008, 06:15 AM   #6
Black06X
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ct
Posts: 140
Yeah, I am going to give them a call when they open up. Thanks for the help. This is my daily driver, so I am going to have to find something for the time being, before I can have them send me a new plug. Thanks again.
__________________
2006 X, RE 4.5" SF lift (3.5" springs) AA SYE + Tom Woods CV shaft, SRC Front+Rear bumper+rock guards, Daystar 1" body lift, 32" X 11.50" BFG Muds on American Racing Teflon 15 X 8's, PIAA fogs, On the way: G2 dana 44's front/rear,Trutrac (rear) and ARB (front), OBA, rear disk brake conversion, BFG 35's
Black06X is offline   Reply With Quote
Unread 05-20-2008, 07:15 AM   #7
abnormal
Platinum Member
 
abnormal's Avatar
1996 XJ Cherokee 
 
Join Date: May 2005
Location: Just around the corner...
Posts: 1,790
Try to find a rubber plug you can put in it or just tape it to keep dirt and water out. I would also change the fluid after you get the plug.
__________________
DURTYROK CAROLINA OFFROAD
abnormal is offline   Reply With Quote
Unread 05-20-2008, 07:25 AM   #8
Black06X
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ct
Posts: 140
you read my mind! Thats exactly what I am doing. I have napa delivering me a couple qts of atf at work, and I found a rubber plu that fits snug for the time being, in case I can't fint out from AA what thread the plug has to be to fit. Thanks for your replies.
__________________
2006 X, RE 4.5" SF lift (3.5" springs) AA SYE + Tom Woods CV shaft, SRC Front+Rear bumper+rock guards, Daystar 1" body lift, 32" X 11.50" BFG Muds on American Racing Teflon 15 X 8's, PIAA fogs, On the way: G2 dana 44's front/rear,Trutrac (rear) and ARB (front), OBA, rear disk brake conversion, BFG 35's
Black06X is offline   Reply With Quote
Unread 05-20-2008, 08:15 AM   #9
Ichabod1960
Have Jeep, Will Travel
 
Ichabod1960's Avatar
2005 LJ Wrangler 
 
Join Date: Jun 2006
Location: Columbia, SC
Posts: 610
Have you checked the pan to see if the bolt may still bouncing around there? You might want to check the FSM to see if the bolt size is in there.
__________________
Drew

Quote:
Originally Posted by Jerry Bransford
There's a great lower division class called "Writing for Effective Communications so you don't go through the rest of your life confusing everyone who reads what you write 101" at Washington State University. I highly recommend it.
Ichabod1960 is offline   Reply With Quote
Unread 05-20-2008, 08:20 AM   #10
flatlander757
Registered User
2003 TJ Wrangler 
 
Join Date: Nov 2006
Location: Dayton, Ohio
Posts: 5,427
If you read the AA instructions for the SYE, you'll find that you probably should have cut a little bit of metal off of the shift rail like I didn't do. The result is a t-case that will leak from the rear housing no matter how hard you try to seal it.

I really should open it back up and take care of that... one day.
__________________
SOLDThe lumbering steel-laden pig - 2003 TJ - 40" LTBs - D60/D70HD - 5.86s - Detroit lockers - 110" wheelbase
Build thread here.

Quote:
Originally Posted by 2006 Sport
Being able to make vroom vroom noises in Tonys Jeep was the highlight of my life.
Currently Jeepless.
flatlander757 is offline   Reply With Quote
Unread 05-20-2008, 08:38 AM   #11
abnormal
Platinum Member
 
abnormal's Avatar
1996 XJ Cherokee 
 
Join Date: May 2005
Location: Just around the corner...
Posts: 1,790
I didnt have to cut it on mine. I checked the clearance and there was plenty of room. The instructions I got said it "might" need to be cut.
__________________
DURTYROK CAROLINA OFFROAD
abnormal is offline   Reply With Quote
Unread 05-20-2008, 08:40 AM   #12
Black06X
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ct
Posts: 140
I don't believe that I needed to trim anything off the shaft on mine. Some transfer cases you have to trim and some you do not, depending on how much the shaft sticks out. It is my assumption that I probably wouldn't be able to shift into 4wd if you have to trim the shaft and did not. If I remember correctly i was supposed to measure the shaft to see if I needed to cut it, and I think it was ok. In any event, it had been in and out of 4wd all winter with the sye installed so I am guessing it is probably fine. I suppose I must not have tightened the plug all the way, and never rechecked it after the install???? Either way, it came loose somehow, and I am just happy I noticed the slow leak this early, instead of all the aft draining out on the highway, and blowing the Xfercase apart. I still need to wait another 30 mins to call AA when they open, so I will try and figure out a aolution from there.

Another person posted to check the FSM for the part. There should not be any spec for that part, as the jeep was not equipped with that from the factory. Thanks for the replies.
__________________
2006 X, RE 4.5" SF lift (3.5" springs) AA SYE + Tom Woods CV shaft, SRC Front+Rear bumper+rock guards, Daystar 1" body lift, 32" X 11.50" BFG Muds on American Racing Teflon 15 X 8's, PIAA fogs, On the way: G2 dana 44's front/rear,Trutrac (rear) and ARB (front), OBA, rear disk brake conversion, BFG 35's
Black06X is offline   Reply With Quote
Unread 05-20-2008, 09:48 AM   #13
Chris_
Registered User
2002 TJ Wrangler 
 
Join Date: Apr 2005
Location: TX
Posts: 2,220
Why is there even a plug in the first place? What's the purpose? You can't get to any of that without splitting the case anyway, and there's just that spring around that piece.

Mine's sealed. I say just loctite a new bolt, and seal it up.

__________________
'02 TJ X Apex Edition
'00 XJ Sport
Chris_ is offline   Reply With Quote
Unread 05-20-2008, 10:07 AM   #14
Black06X
Registered User
2006 TJ Wrangler 
 
Join Date: Jan 2007
Location: Ct
Posts: 140
I had the exact same thought. I just ordered another plug from AA, it was a whopping $2.00 haha. I am just going to jam a rubber plug in there for now that I found at work, and just tape it in there until I get the correct plug in a couple days. When the new plug comes, Im going to loctite it and be done with it. I know this kit has other applications, so maybe there is a need for this plug on an XJ or something like that...Like you, I can't see a use for this plug as well, b/c like you said, you need to take it apart to fix anything anyway, and that hole isn't really big enough to look inside for any kind of damage, and you can't see anything in there anyway. I guess I just didn't tighten it sufficiently, which really bothers me b/c I never do stupid things like that Oh well, I am just happy it wasn't a leak at the seam, b/c I didn't want to have to take that thing apart again and re-silicone it.
__________________
2006 X, RE 4.5" SF lift (3.5" springs) AA SYE + Tom Woods CV shaft, SRC Front+Rear bumper+rock guards, Daystar 1" body lift, 32" X 11.50" BFG Muds on American Racing Teflon 15 X 8's, PIAA fogs, On the way: G2 dana 44's front/rear,Trutrac (rear) and ARB (front), OBA, rear disk brake conversion, BFG 35's
Black06X is offline   Reply With Quote
Reply
Thread Tools


Suggested Threads





Jeep, Wrangler, Cherokee, Grand Cherokee, and other models are copyrighted and trademarked to Jeep/Chrysler Corporation. JeepForum.com is not in any way associated with Jeep or the Chrysler Corp.