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  #1  
Old July 30th, 2012, 05:53 PM
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aaron lam
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Reseal Transfer Box

Just resealed the transfer box with Really Right Stuff... how long should I wait before filling it back up with oil?
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  #2  
Old July 30th, 2012, 09:56 PM
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Chris
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I wish you'd actually deal with the leaks rather than cover them up.
Any idea what that stuff does to all the bearings and gears?
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  #3  
Old July 30th, 2012, 10:18 PM
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Quote:
Originally Posted by Rocky View Post
I wish you'd actually deal with the leaks rather than cover them up.
Any idea what that stuff does to all the bearings and gears?
What are you talking about? Right Stuff is a gasket maker used for things like the access plate.
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  #4  
Old July 31st, 2012, 12:02 AM
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My truck's got nothing but gorilla tape and rust holding it together!

This is what I did... just for future reference and some tips that I learned.

1. Remove fill cap... I used a 1/2 socket driver... a bit hard to get to but an extension will help you get away from the brake drum. Remove drain plug and drain.

2. Remove the 10 bolts to the transfer plate (10mm). 3 are behind the y-pipes and hard to reach without dropping the pipes but doable (this references a 97). A ratcheting wrench and universal joint was helpful. Surprisingly, something so drenched with oil was still hard to get off... it needed a couple coats of PB Blaster to coax it.

3. I used a putty knife and lightly tapped it in between the plate and the transfer case. Popped off after that.

4. Cleaned the prior Right Stuff gasket off with a razor carefully... I used a window scraper thingy to keep it flat. The plate has a line down the middle of the outer edge (I presume to cause more of a seal) so you have to do each side separately. I wiped some more with a little goo gone and then degreaser... left to dry.

5. Probably could have gotten new bolts as mine has some deposits in the thread... also left over Right Stuff on the bolts. I used a nut and wire brush to clean the threads and made sure they went on smooth by hand. Applied hylomar to the threads.

6. Lined the cover plate (right on that line) and around the bolt holes with Right Stuff gasket maker like icing on a cake.

7. Carefully put back on.

8. Let dry for SIX HOURS!!!

9. Hylomar'd the drain plug and fill cap and put back on. Filled with Royal Purple 75w90. I needed a hand pump to get it in there and used about 2.25 qts. I was careful not to spill that expensive stuff.

Hopefully that was all right!!! I guess we'll see tomorrow when I drive around. I'll let you know if it leaks again. Let me know if I did something wrong.
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  #5  
Old July 31st, 2012, 08:43 AM
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Matthew
1983 110 200tdi 3 door soft top
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Quote:
Originally Posted by aaronlam View Post
My truck's got nothing but gorilla tape and rust holding it together!

This is what I did... just for future reference and some tips that I learned.

1. Remove fill cap... I used a 1/2 socket driver... a bit hard to get to but an extension will help you get away from the brake drum. Remove drain plug and drain.

2. Remove the 10 bolts to the transfer plate (10mm). 3 are behind the y-pipes and hard to reach without dropping the pipes but doable (this references a 97). A ratcheting wrench and universal joint was helpful. Surprisingly, something so drenched with oil was still hard to get off... it needed a couple coats of PB Blaster to coax it.

3. I used a putty knife and lightly tapped it in between the plate and the transfer case. Popped off after that.

4. Cleaned the prior Right Stuff gasket off with a razor carefully... I used a window scraper thingy to keep it flat. The plate has a line down the middle of the outer edge (I presume to cause more of a seal) so you have to do each side separately. I wiped some more with a little goo gone and then degreaser... left to dry.

5. Probably could have gotten new bolts as mine has some deposits in the thread... also left over Right Stuff on the bolts. I used a nut and wire brush to clean the threads and made sure they went on smooth by hand. Applied hylomar to the threads.

6. Lined the cover plate (right on that line) and around the bolt holes with Right Stuff gasket maker like icing on a cake.

7. Carefully put back on.

8. Let dry for SIX HOURS!!!

9. Hylomar'd the drain plug and fill cap and put back on. Filled with Royal Purple 75w90. I needed a hand pump to get it in there and used about 2.25 qts. I was careful not to spill that expensive stuff.

Hopefully that was all right!!! I guess we'll see tomorrow when I drive around. I'll let you know if it leaks again. Let me know if I did something wrong.

Very thorough post. I used permatex black RTV with the same results
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  #6  
Old July 31st, 2012, 09:39 AM
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Brian Jones
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Lets us know if your leak free. I've got the same leak and hoping a reseal of the inspection plate does the trick.
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  #7  
Old July 31st, 2012, 04:15 PM
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Nick Vogel
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Awesome right up. I hope it works. Guys that saw these things new said they weeped oil when they came off the truck....
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  #8  
Old July 31st, 2012, 04:38 PM
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Quote:
Originally Posted by 97-D90-736 View Post
Guys that saw these things new said they weeped oil when they came off the truck....
I've heard that too. All I have to say is: YAY!
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  #9  
Old August 1st, 2012, 11:22 PM
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Jason Lavender
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Nice post. I resealed my inspection plate last month on the 110, did exactly what you posted essentially. Good news is the inspection plate hasn't leaked since. Bad news is it made me realize the leak was actually coming from what I believe to be the intermediate shaft in the tcase.
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  #10  
Old August 1st, 2012, 11:55 PM
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Carl Jonsson
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Great write up!

Looking at your photo with the arrows makes me think my weeping leak also might be the inspection plate. I have always thought it was front or rear input seals because someone mentioned that as common. I just changed the oil but come next change i'm going to put a new gasket on and see if the leak stops. Thanks for the tip!


Quote:
Originally Posted by aaronlam
My truck's got nothing but gorilla tape and rust holding it together!

This is what I did... just for future reference and some tips that I learned.

1. Remove fill cap... I used a 1/2 socket driver... a bit hard to get to but an extension will help you get away from the brake drum. Remove drain plug and drain.

2. Remove the 10 bolts to the transfer plate (10mm). 3 are behind the y-pipes and hard to reach without dropping the pipes but doable (this references a 97). A ratcheting wrench and universal joint was helpful. Surprisingly, something so drenched with oil was still hard to get off... it needed a couple coats of PB Blaster to coax it.

3. I used a putty knife and lightly tapped it in between the plate and the transfer case. Popped off after that.

4. Cleaned the prior Right Stuff gasket off with a razor carefully... I used a window scraper thingy to keep it flat. The plate has a line down the middle of the outer edge (I presume to cause more of a seal) so you have to do each side separately. I wiped some more with a little goo gone and then degreaser... left to dry.

5. Probably could have gotten new bolts as mine has some deposits in the thread... also left over Right Stuff on the bolts. I used a nut and wire brush to clean the threads and made sure they went on smooth by hand. Applied hylomar to the threads.

6. Lined the cover plate (right on that line) and around the bolt holes with Right Stuff gasket maker like icing on a cake.

7. Carefully put back on.

8. Let dry for SIX HOURS!!!

9. Hylomar'd the drain plug and fill cap and put back on. Filled with Royal Purple 75w90. I needed a hand pump to get it in there and used about 2.25 qts. I was careful not to spill that expensive stuff.

Hopefully that was all right!!! I guess we'll see tomorrow when I drive around. I'll let you know if it leaks again. Let me know if I did something wrong.
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  #11  
Old August 8th, 2012, 11:28 PM
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So 150 mi... a little off road running through low and high gears... there is a little bit of a weep from that one bottom bolt. Oh well. It's 100x times better than before and nothing dripping on the ground anymore but when I touch that bolt, it's wet.

If anyone figures out how to seal the transfer box better... would love to hear!
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  #12  
Old August 9th, 2012, 12:18 AM
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No... this bolt... it's just this one bolt.
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  #13  
Old August 9th, 2012, 12:32 AM
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Is your breather clear?
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  #14  
Old August 9th, 2012, 12:37 AM
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aaron lam
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errr. Not sure. How do you know or check?
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  #15  
Old August 9th, 2012, 12:52 AM
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aaron lam
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Quote:
Originally Posted by JSBriggs View Post
Reseal the shank of that bolt with 'the right stuff'

-Jeff
Next drain. There's $50 worth of Royal Purple in there!!
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