NP208 rear slip yoke leaking

[xCaliK5x]

So now that I resealed the front output shaft on my 208, the t-case will now hold fluid, well, atleast the leak has moved further up. I noticed ATF dripping from my rear driveshaft. The seal on the tail shaft is dry, but the plug in the slip yoke is wet. I have read online there is some sort of seal that is supposed to be used on either the splines on the t-case or in the slip yoke. I can not find a thread of what it looks like or how to get one or repair it. Any help? Thanks again guys, this truck is a P.I.A. but I will get it mended and on the trail soon. I refuse to give up, I am determined (or foolish!)

 

[sweetk30]

brake clean off slip yoke. then dab on a bit of regular old rtv.

and dont do the splines on a SLIP shaft . then it wont slip anymore.

 

[xCaliK5x]

Ok, cool. I will do it when I get it here to the shop this weekend.

BTW, has anyone actually RTV'd the slipyoke splines before?

 

[rcamacho]

The slip yoke tends to pressurize when the drive shaft compresses. If the yoke plug is leaking you may have to tap it out, remove the rubber seal and then weld it in. That's what mine took to seal. RTV, Epoxy were fruitless.

 

[xCaliK5x]

I haven't had one apart, but from what I read, which means nothing, there is one spline missing to allow the air to move in/out of the end. Having never taken the shaft out of one, I have no idea if that is true......

 

[rcamacho]

Some have a spline relief, some don't. Either way, on 208 there tends to be alot of fluid in the yoke. ATF will bleed past the splines but it will create hydrostatic pressure. I've tested this with a spare 208 main shaft... Either way a brazing job or wire weld works fine if you keep the heat down.

 

[Stomis]

Ya have 5 pints or 5 quarts in your tcase?

 

[xCaliK5x]

I filled it until it ran out of the fill plug hole, let it level off and put the plug back in. As far as quart/pint count, It was around 4, 4.5 maybe. I had to keep filling an old gear oil bottle and squirting it in. The leak seems to have stopped on its own. I will still check it. Its been on hold the last few weeks, been busy.

On a side note, the pan gasket really leaks now, most of the bolts were loose. Not "loose" a little, but several bolts were a few turns. So I snugged them down, now it leaks worse.

 

[obijuan]

hey man, if it aint leakin its empty.

 

[xCaliK5x]

hey man, if it aint leakin its empty.

Exactly.

 

[Stomis]

I filled it until it ran out of the fill plug hole, let it level off and put the plug back in. As far as quart/pint count, It was around 4, 4.5 maybe. I had to keep filling an old gear oil bottle and squirting it in. The leak seems to have stopped on its own. I will still check it. Its been on hold the last few weeks, been busy.

On a side note, the pan gasket really leaks now, most of the bolts were loose. Not "loose" a little, but several bolts were a few turns. So I snugged them down, now it leaks worse.

To follow this up with some personal experience...

What happened to you is caused by too much seal pressure from over filling the case. Slip yoke transfer cases arent something you fill til theyre pouring out like a trans or rear.

I learned this the hard way. Had a 208 rebuilt completely even sleeved the slip yoke for a fresh seal surface. I put 5 quarts in it and the thing leaked like a civ. Hell it leaked out the front output because the sleeved and resealed slip yoke had such a good seal on it.

Once the thing drained down to the proper level it stopped leaking. Typically on a used transfercase your slip yoke seal will be your weak link and it will leak from there.

The moral of the story is that you can overfill a transfer case, especially a slip yoke case.

Its 5 pints not 5 quarts.