My np241 has some Leaks Should I just rebuild

[phrogs]

I have the Transfer case out of the truck for my transmission rebuild.


The Tcase has been leaking at the split between the two halves and at the output seal to the driveshaft.

I Started cleaning the Tcase last night and was able to remove some of the RTV that was pushed out from the two halves, it is of course very dirty at the leak origin but the case is so damn clean in that area now, I really just want to fix the leaks but If Im already pulling it apart should I rebuild it?

Now It would be my first one so I need a little help with directions on this thing so I can read over it. Any how to's? I couldn't find anything in my searchs

Does anyone know of limitations on the parts some kind of list of what to check while Im in there to verify if my parts are good or not?

I'm just not sure what to check inside this thing to make sure it is good other than the seal leaks

 

[496truck]

Most common failure points are the shift forks and pads on the forks. I have taken the case halfs apart and resealed them before with black RTV. Seal replacement is pretty straight forward.

But when my t-case failed while driving down the street, and at the time the K5 was my daily driver, I pulled the whole unit and dropped it off at a trans shop to be rebuilt. Didn't have time for it to be apart and figure out the problem and order parts and such. So I have no specific knowledge of the inner workings or part replacement. I have gotten very good at R&Ring a t-case on this truck though.

I have no good articles to point you towards.

 

[phrogs]

If I unbolt the tail shaft and the back of the case to re seal it Im not going to drop a ton of needle bearings or anything am I ? If I can pull these off and just take a look inside and check things out then reseal thats What I'd like to do since Im about broke still awaiting a new Job.

 

[496truck]

Needle bearings, no. I had mine laying down with the tailshaft pointed up. Support the case with a 2x4 or something so that it isn't resting on the front output, if not then the front output shaft will try to push upwards and you may have to fight with it to realign everything.

Remove the 4 bolts for the tail housing and slide that off. Remove all the bolts around the case and separated them. Clean and reseal with black RTV. I vaguely remember something falling back into the case when I pulled them apart. It was something trivial and easy to overlook so watch out for that. Make sure both shafts are aligned into the case half during reassembly. If you have to force it, something is wrong.