I've got a long trip from Western MA to Sturgis MI coming up soon and my transfer case is leaking from the housing mating surfaces and the tailshaft housing mating surface. Somebody told me there is no gasket but to use RTV sealer....is that true? or is there actually a gasket I should buy.

Thanks!

 

All my different Mopar transfer cases never showed any part #'s at the dealer for gaskets and they always said just to seal it. but the local Chevy dealer would always have them for the same transfer case models(ie your New Process 241). You might have to find which GM models had that case if you run into a lazy parts man! For instance, on my Trailduster w/NP 208, I just told them I needed a gasket for the Blazer. I always prefer a good fiber gasket to RTV, it just makes me feel better knowing there is something pinched there! PS - you can also cut the said gasket, and slip it between the two parts, with the cut at TDC of course, and then not even completely remove the tail housing(or the other end) to install if you need. Good luck, hope you can find a gasket! :-)

 

I would just use RTV. They come from the factory that way. Use the black stuff and you will be just fine. It isn't hard at all to split it and reseal it either. Also, make sure and check that it isn't a crack that is causing the leak. I've seen two speedo housings crack, one was out of the blue, the other (mine) was subject to an impact. Good Luck!

 

the manual said to use RTV, so I did, plus like he said it comes from the factory like that. Ur gonna want to buy a new rear output snap ring before u take the t-case apart because it's a very important piece and will usually distort even after taking it off once. It's only about $4 and ur dealer should have it, or have it shipped to them the next day.

 

I recently had the all of the output seals replaced so they probably did the snap ring then? Will taking the tailshaft housing off distort it still?

 

Here's a pic of how far I got without taking the snap ring off. Basically just the yoke housing can come off, the second tailshaft housing can't, and the maincase can't come apart either. It's worth getting a new snap ring because it holds the mainshaft in alignment which is critical. It's a heavy little snap ring and will distort after taking it out once most likely. Ur dealer can have it the next day if u call today, it's only $4.

 

I'm pretty sure my tailshaft housing mates directly to the maincase housing. Is your transfer case the 241 dld and not the dhd? Mine has the PTO cover and a long tailshaft housing. I've read up on a transfer case saver kit that is supposed to hold the snap ring in place better, but i've also read it doesn't work on my transfer case. I ordered the snap ring though....2 bucks. Thanks for the pic. Will I be able to get the main case apart without too much of a problem?

 

I have a 241 DHD with the pto cover. I just followed the steps in the manual for disassembly. I used a 2001 service manual, so there the exact same t-case's. It wasn't hard at all to take it apart, I had to put a new input shaft in for my swap so I disassebled pretty much everything inside.