Transfer Case output shaft end plug leaking - DodgeTalk : Dodge Car Forums, Dodge Truck Forums and Ram Forums
 
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#1 Old 08-30-2010, 11:54 AM
paulroosen
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Transfer Case output shaft end plug leaking

2003 Ram 3500 4x4: The output Shaft from the transfer case is leaking from the center. The dealer says there is a plug that is non-repairable.
Is there a way to seal this plug? or Di I need to get a new output shaft?
The Transfer-case output shaft seal is fine (no leaking)
Thanks
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#2 Old 08-30-2010, 11:07 PM
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I call BS. That just makes no sense. Dealer prob just don't want to mess with it. If there was a plug, then where did it go ? Did it go inside the transfer case ? Did it fall out ? Either way, you can go to Valu Hardware Store & buy a small rubber cork for $.15 cents. Cut it carefully to fit the hole & bam your done. I would be concerned if it fell into the tcase. Sounds like a drain & refill is in order as well. It should get chewed up after a while & come out with the fluid.

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What, you ask, is the difference between a Dodge Ram and a PowerWagon ?? PW frame part # 55398868AC---Reg 2500 #55398813AC
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#3 Old 08-31-2010, 01:36 AM
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I agree with TwinStick I don't see why what he said wouldn't work.
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#4 Old 08-31-2010, 09:09 AM
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The plug isn't missing, just leaking. Profusely... about 1-quart in a month.

Thanks. I will try to seal it from the inside with some form-a-gasket goo.
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#5 Old 08-31-2010, 11:07 PM
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Take some pics & let us take a look at it please.

08' PowerWagon w/6-speed manual G-56. 05' 30' toyhauler camper.(10,500lbs)
Hellwig LoadPro 35 bolt on 4 leaf helper springs.
No honey, I'm NOT done buying shit for the truck yet !!!
PurpleCrainium Diff Guards
K&N air filter --- WeatherGuard 20" black bed toolbox.
winch TPC bypass
Dual battery set up w/2 Sears DieHard Platinums-Gp 65 under hood-Gp 31 Marine deep cycle in bed toolbox w/plug-n-play set up. Custom 2000/4000w inverter set up w/quick connect. Triple bike mounts above the bed- custom made by me.
Crapload of recovery gear-always subject to adding more.
Fab Four rear bumper. Soon to be- a BuckStop Baja front bumper.--Temporarily on hold, see reason below.
Installed: Borgeson #000951 steering shaft. PSC steering brace(notched for PW by Rusty-thanks bud). Carli HD CroMo adjustable track bar. Carli CroMo control arms. Carli HD upper & lower balljoints x 2 sets (replaced under warrenty) & triple sealed u-joints in front axle shafts & rear driveshaft. Moog HD tierod ends x 4. Running total is now $4800. Yup, now i'm broke !!!


What, you ask, is the difference between a Dodge Ram and a PowerWagon ?? PW frame part # 55398868AC---Reg 2500 #55398813AC
About 2" taller, 12,000lb winch w/mounting brace between framerails,electronic disconnecting swaybar(for awsome articulation),electronic locking axles front & rear(for true 4-wheel drive),tow pkg, fully skidplated,forged one piece Alcoa rims w/internal beadlock lips,larger diameter(one ton) axleshaft in rear,160 amp alt,HD battery,4.56 gears,low range electronic recalibration of gas pedal sensitivity,more but thinner leafs in rear spring pack(for better articulation), 33" BFG All-Terrain tires. 78.016:1 crawl ratio. All for $6100.00 more! Oh yeah, almost forgot-Bilstein shocks. Gear ratios: 1st 6.29:1 2nd 3.48:1 3rd 2.10:1 4th 1.38:1 5th 1.0:1 6th .79:1.. Rev 5.74:1.
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#6 Old 09-01-2010, 11:07 AM
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Pictures would really help. I can not visualize this. In my experience, the drain plugs are on the bottom of the case (not near the outputs). The fills are usually in the middle of the case.

When you say output shaft, are you talking for the front driveshaft, or the rear driveshaft?

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#7 Old 09-02-2010, 10:04 AM
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The rear output shaft is leaking
This is a long-bed with a 2-piece driveshaft (5-peice if you count the output shaft, the front half, a short piece with splines, the rear half, and the rear yoke that connects to the differential)
There are three U-Joints, and a carrier bearing.
The leak is in the center of the shaft before the U-joint near the transfer case.
I looked through the DR service manuals. I couldn't find a reference to this output shaft.
I was going to take it off this weekend and try to seal the shaft from the inside.
Thanks
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#8 Old 09-02-2010, 04:41 PM
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I'm sorry I'm pretty dense too, are we talking about the slip yoke that goes into the transfer case, and leaking though the back of it, though the splines? I have seen this on transmissions.

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#9 Old 09-02-2010, 04:46 PM
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I'm gonna go with needing a pic on this one.

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#10 Old 09-02-2010, 06:45 PM
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trying to think but dont know. need pics to see. i was thinking the seal on the output shaft other than a plug. but idk. pics brother!!!

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#11 Old 09-02-2010, 11:54 PM
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I think I am getting what he is saying.

Seems like a problem here. During the machining of driveshafts they have the center cut out for whatever reason. There is usually a brass plug that is pressed in to keep fluid from leaking out of the center of the output shaft.

Kind of a representative image here. As you can see there is a brass plug in that spot.



Back in the early 90s chrysler had a huge recall on Eagle talons and plymouth laser AWD because of that plug leaking and causing accidents from the Tcase running dry and locking up all 4 wheels.

This is how we fixed it. Take out the driveshaft and fill the end of it with a little bit of rtv. When I say little bit, you don't want to fill it full and then slam it into your tcase. You don't want the squished out and left over pieces of rtv floating around in your tcase. Then clean the grime and dirt off the other end and spread it around the outside perimeter of the plug. This should take care of any leak that you have at that spot.

-Ben
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#12 Old 09-06-2010, 09:08 PM
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WOW !!! What a chicken sh** design that is. I mean really, what are they saving ? Like $.50 worth of metal ? I just don't understand why anyone would design it like that at all.

08' PowerWagon w/6-speed manual G-56. 05' 30' toyhauler camper.(10,500lbs)
Hellwig LoadPro 35 bolt on 4 leaf helper springs.
No honey, I'm NOT done buying shit for the truck yet !!!
PurpleCrainium Diff Guards
K&N air filter --- WeatherGuard 20" black bed toolbox.
winch TPC bypass
Dual battery set up w/2 Sears DieHard Platinums-Gp 65 under hood-Gp 31 Marine deep cycle in bed toolbox w/plug-n-play set up. Custom 2000/4000w inverter set up w/quick connect. Triple bike mounts above the bed- custom made by me.
Crapload of recovery gear-always subject to adding more.
Fab Four rear bumper. Soon to be- a BuckStop Baja front bumper.--Temporarily on hold, see reason below.
Installed: Borgeson #000951 steering shaft. PSC steering brace(notched for PW by Rusty-thanks bud). Carli HD CroMo adjustable track bar. Carli CroMo control arms. Carli HD upper & lower balljoints x 2 sets (replaced under warrenty) & triple sealed u-joints in front axle shafts & rear driveshaft. Moog HD tierod ends x 4. Running total is now $4800. Yup, now i'm broke !!!


What, you ask, is the difference between a Dodge Ram and a PowerWagon ?? PW frame part # 55398868AC---Reg 2500 #55398813AC
About 2" taller, 12,000lb winch w/mounting brace between framerails,electronic disconnecting swaybar(for awsome articulation),electronic locking axles front & rear(for true 4-wheel drive),tow pkg, fully skidplated,forged one piece Alcoa rims w/internal beadlock lips,larger diameter(one ton) axleshaft in rear,160 amp alt,HD battery,4.56 gears,low range electronic recalibration of gas pedal sensitivity,more but thinner leafs in rear spring pack(for better articulation), 33" BFG All-Terrain tires. 78.016:1 crawl ratio. All for $6100.00 more! Oh yeah, almost forgot-Bilstein shocks. Gear ratios: 1st 6.29:1 2nd 3.48:1 3rd 2.10:1 4th 1.38:1 5th 1.0:1 6th .79:1.. Rev 5.74:1.
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#13 Old 09-07-2010, 11:10 PM
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The outer seal on these transfer cases leaking is more common. I hear about it alot, when I bought my 03' Cummins the transfer case was shot from being run out of fluid.

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#14 Old 09-09-2010, 10:28 PM
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Quote:
Originally Posted by TwinStick View Post
WOW !!! What a chicken sh** design that is. I mean really, what are they saving ? Like $.50 worth of metal ? I just don't understand why anyone would design it like that at all.
Not saving on metal, the hole is needed for the machining of the splines on the yoke.
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#15 Old 09-09-2010, 10:33 PM
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The new ones were designed not to leak(so i was told). My '06 had a leaking one that I had to replace. The new one has been on for 4 years and not leaked.... yet.

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#16 Old 09-09-2010, 10:44 PM
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They could have just brazed them for a couple of pennies and been done with it. Which might cause a stress because of the weld in that area though from the heating. These are just press fit plugs though like freeze plugs. I bet you could just press out that old plug and They do make rubber coated brass plugs now.
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