hey guys, i need some help/opinions on what to do about my t-case, b4 u tell me to seach the forum, i've been searching and haven't quite found the answer i was looking for....here's the scoop, one day i noticed a scraping noise coming from my truck, thought it was bad u-joints in the front axle since they also click/pop when i turn in 4wd, so i just started to ignore it, curiosity led me to believe that it was something else, felt floor shifter and sure enough i could "feel" it in the shifter, had to be coming from t-case, removed fill screw and stuck my finger in there, couldn't feel anything, removed bottom screw....bone dry!!, needless to say i felt like an a$$, got some ATF+4 and started filling it up, well when i was on my 2nd quart, i noticed fluid started running from somewhere by the front drive shaft, waited for it to stop, wiped it off and found a pretty decent crack in the case.............

now here's the thing, it will still hold some fluid for now and everything shifts in and out with no problems, i talked to my dad n he told me that i could epoxy the crack so i could fill it completely since it seemed that everything else was fine, he suggested that maybe i could get it welded, or get a new one...............

i like what jb conversions offers, but at the same time dont have $900 to spend on it, may look into getting one from a junk yard, but i think that the internals of mine are still good, the problem is just the case itself.......any advice or help????

 

I wouldn't know about epoxy, but you go to a machine shop and see if they can braze it for you and ask what that would cost.

If you're going to go the epoxy route, I'd look into JB Weld.

 

The NP transfer cases are NOTORIOUS for cracking. The GM's usually crack the tail shaft housing and the Dodges crack the case it self. Try your local transmission shop or junk yard, a used case half should be pretty easy to find. The NP transfer cases are very simple to take apart and put back together. I wouldnt recommend repairing the case.

When you get it all back together and working properly.... CHECK YOUR FLUID MORE OFTEN!

 

having been a poor student... i'd clean the cracked area with a little brake cleaner, then put some JB Weld on it. put a piece of duct tape over it to keep it from sagging off. let it dry and remove the duct tape. add a second coat if necessary. fill it up and see if it leaks. if it doesn't your done. if it does, then you'll need to try something else. i've fixed everything from gas tanks to headlights to mufflers, to chainsaws, to canoes with jb weld.

 

put a np 241d out of a rubicon you will get a stronger case and a 4:1 low range and slip yoke elminator to will have to make custom shafts but would be worth it or just find a new transfer case

 

thanks for the suggestions, right now the truck is in the shop for tie rod ends and sway bar, should get it back by tuesday, there's a welding shop bout 5 mi from my house, i'm gonna stop there n see what they say (i donno if they can weld it w/o taking it off), 2nd try would be to go the jb weld route, n then save in the summer n fix it permanent.......

 

I had a cracked transfer case in my ford a while back. I didn't have much to spend on it so I tried to fix the crack. First I tried to taking the thing to a machinist to have it welded. The case is cast aluminum and other materials so I thought it could work. The guy tried to fix it but the weld just cracked after it cooled. I would recommend the JB as a quick fix until you find a new case.
The thing is that your gears and chain could be worn from not having any lubrication. I'd recommed finding another one from a junk yard and parting both out to make the best t-case. They are fun to work on.

 

I agree with dhvaughan. I have a couple of hairline cracks in mine. Almost like the two halves were over torqued when bolted up. It would leak some and I cleaned smeared some RTV over all of the cracks. It stopped the leak. It's been that way since I bought it 130,000 miles ago.

 

well just wanted to update u guys, i went the jb weld route and it sealed up pretty good, there was one spot that i couldnt get near the front drive shaft output so it still leaks a little, i guess it will till the fluid settles below that area, as for a permanent fix....i wanna see how good this holds up and was considering going the jb conversion route but don't know too much about cv rear driveshafts b/c on their site it says thats what i would need to do the swap...thanx for everyone's input...

 

But my gears didn't survive they are screwed I like the idea of swapping out for a stronger one and would like more info on the 241 if you have any thanx