Transfer case adapter gasket replacement instructions needed

Hi,

I would be happy to provide the directions for removal and replacement, but I need to confirm which model transfer case you have. There are several options that were available.

If you look at the rear of the transfer case, there should be a steel label attached to it. Locate that and let me know which model you have.

I attached a pic below showing what it may look like.

Let me know what you find.

Joe

See pic below.

I really appreciate your response. I will get you that model number as soon as I get home from work today.

Okay. so, I found the tag. But I have a question. If I have transmission fluid leaking where the transfer case bolts to the transfer case adapter does that mean I have a bad seal?

Hi,

If there is a leak, chances are it is a seal/gasket between the two components.

You have the NVG 246 transfer case manufactured by New Process (New Venture Gear). These are usually very reliable.

Regardless, I attach the directions below specific to this transfer case for the removal and replacement. Let me know if this helps or if there is anything I can do to help.

Take care,

Joe

See pics below.

Okay. So, I successfully removed the transfer case. Now when I spin the shaft should I hear the slightest tinging noise inside the transfer case or is that a problem? Also, where the encoder motor mounts to the transfer case, is there an o ring or gasket there that could leak fluid?

Man, I just want to say how relieved I am to have found this website. I had Googled and Googled and could not find a complete walk through. It took forever to find half a diagram of a transfer case. So, thanks a lot for sharing the knowledge.

Hi,

First, you are very welcome. Also, the ticking you hear is likely the gears turning against each other which is normal.

As far as a gasket, there should be a rubber gasket that is reusable. I attached the directions for the removal and replacement of the encoder below.

Let me know if this helps.

Take care,

Joe

See pics below.

Very helpful. The encoder motor works fine but I’m wondering. If I replace the seal on the output shaft of transmission would that rubber gasket on the motor possibly still be leaking transmission fluid. I don’t want to put it back together to find that the encoder motor is leaking too. Also do you suggest any other service that could or should be done while I have the transfer case out?

Hi,

As long as the gasket is in good shape and properly torqued, it shouldn't leak. When it's apart, the only thing you can do is a general inspection.

If you notice anything, let me know.

Take care,

Joe

Would that be the output shaft seal inside where the transfer case mounts to the adapter?

The output shaft is at the rear of the transmission. I attached a pic below. The highlighted area is the shaft, and the circled part is where the seal will be located.

Is that what you are referring to?

Let me know.

Joe

See pic below.

Yes, that is it, there is transmission fluid coming from around that seal. So, I need to replace that seal, correct?

Yes, the seal should be replaced. When you do this, make sure it seats fully and lubricate the seal with ATF before installing the transfer case and the shaft that connects to it should be inspected as well.

Let me know if you have questions.

Take care,

Joe

Okay, now I’m working on this in my gravel driveway. Say a piece of dirt got on the shaft. What do you recommend cleaning the shaft with to ensure there is nothing in between the splines? Referring to the driveshafts as well.

Also I’m wondering how do I remove the seal?

Also I’m wondering how do I remove the seal

Hi,

As far as the seal removal, they make a seal removal tool. See pic below. It's very basic.

Use something like brake cleaner that is very effective to clean parts. It evaporates really fast, so you can use it for this.

Let me know how things turn out for you.

Take care,

Joe

Is the seal around that shaft the one I need to replace?

Hi,

I'm not seeing a seal. I believe I'm seeing a damaged O-ring. Take a look at the attached pic and let me know if that is what you are referring to.

Also, if there is a leak between the two components that are allowing fluid to enter the transfer case (transfer case overfull) there is an input seal on the transfer case side that can fail and cause that to happen.

Let me know.

Joe

See the pic and let me know if what I highlighted is what you are referring to. As far as the aforementioned post from me, the tool indicated isn't for that type of seal. I was thinking output shaft seal.

I’m thinking that I just need to replace the gasket in between the transfer case and the extension housing. Because the transfer case wasn’t overfull. transmission fluid was leaking from between the transfer case and ext. housing but not getting past the seal on the transfer case.

As far as that last picture there is larger o-ring on the transmission side of the extension housing and If I’m understanding correctly a smaller o ring around that shaft. Originally, I thought that transmission fluid wasn’t supposed to be getting past the shaft in your last picture, but I noticed a tiny port under that shaft. I think that port allows the extension housing to fill with transmission fluid and the seal on the transfer case input shaft keeps transmission fluid from entering the transfer case, correct?

Hi,

Yes, that is correct. If you end up with the ATF getting into the transfer case, it is the result of a faulty input shaft seal on the transfer case.

Let me know how things work out for you.


Joe

Hey Joe, I just wanted to say thanks for all your help. I got everything put back together and no leaks. Now I noticed that the rear drivers side u bolts are about shot. One has corroded all the way through one side and the other isn’t far behind. What can you tell me about replacing the U bolts?

Hi,

You are very welcome. I'm glad you got it back together and it's not leaking.

When you say U-bolt, are you referring to a universal joint or the long bolts that go around the axle securing the leaf spring?

See pic 1 below. Is that what you mean?

Let me know.

Joe

See pic below.

The ones securing the leaf spring.

The ones securing the leaf spring

It’s the piece you highlighted in the last picture.

Hi,

That is straightforward. I attached the directions below. I'm not sure what you have as far as jacks, but the directions indicate lifting the truck on a rack and then supporting the axle separately.

If you don't have a rack, lift the rear off the ground and place safety jacks on each side of the axle assembly. Then, lower the vehicle to where the axles are touching the axle just enough to take the weight of the axle. Don't put a load on the axle.

Let me know if you have questions.

Take care,

Joe

See pics below.