Outer Limits 4x4 Board

Hey guys, I have had my transfer case rebuilt and well Im a little disappointed. I heard some sorta scratchy/grinding noises coming from below and have put it up of the ground to find the noise and it was coming from the drum brake on the back of the transfer case. First thing though is its 3rd day back on the road and nearly any place where there is gaskit is seepage or major bubbles of oil forming into drips on my driveway as in its leaking pretty much worse than before I sent it in.....? Second the rear shaft that the Drum brake attaches to seems to have a bit of play after pulling the drum of. Now if you look at the pics I found what the noise was it was the inside of the drum rubbing on the bracket for the shoes you can see the bare metal. So when I get on the accelerator it pulls the shaft in a little but enough that its causing other parts in the assembly to rub and making noise and heaps of heat. So now Im not happy and will be taking it back to the business to hopefully fix it, so by all means I wish to sort this out and certainly don't want this to come across as a business flaming thread. Second I want to know what sorts of sealants others have used so I can ask what they used and what not.

So Im going in tomorrow to give back the transfer case but, I want to know from those that have rebuilt their transfer or done the transfer gear install what you guys used to as well as the gaskit to get a good seal. I have also put in oil obviously and used the recommended blend from Penrite which I have previously used before. Other than that the output shafts aren't leaking which is good cos thats where they were leaking.

So from this pic the shaft is pushed in, the rubber seal is sitting flush


This one it is pulled out, the rubber seal has a lip.... Is 2-3mm to much play........?


And if you look at the shoe bracket it is ground down from rubbing, and a little slightly on the springs....? Now before it went back on there was no marks on the inside of both the drum and that bracket.

That movement doesn't look right to me especially if it is causing metal on metal contact.

I used the paper gaskets and "PRO SEAL" 'Aluminium RTV Silicone INSTANT GASKET'.
I got it fromSupercrap I think

hi bud.
as you said im not flaming the place that done it but....


what sort of rebuild is that?


the shaft should have no play in and out or up or down at all. the case also looks messy as. i would seriously ask yourself what was meant to be rebuilt in the case and make sure they done it.

cheers mark

I haven't used it yet but I bought permatex ultra grey undert he instruction of this page.

http://www.trail-gear.com/tech/zuk65gears/index.html

I certainly wouldn't be happy if I'd paid for that sort of work.

After I installed my gears and bearings I just gave the case a good clean and replaced the gaskets. No sealant used at all - and a few months later I have had no leaks what so ever. I don't have a drum brake on my t-case, but it obviously shouldn't be rubbing like that.

I would take the case in and have a quiet chat to the man in charge. If he has any sort of decency, or reputation to uphold, then he will fix it up for you quicksmart.

Yeah well the business is apparently reputable, and does a lot of great work with gear boxes, Auto's diffs and other transfer cases but I think they have a sad lack of knowledge on Sierra transfer case......?

I hope they can take it all in tomorrow and sort it out.

MUD-PIGSIERRA wrote:I hope they can take it all in tomorrow and sort it out.

If they don't you might need to turn the quiet talking into some slightly louder foot stomping.
That kind of end result is unacceptable from any business. Hopefully you get it all sorted.

Hey guys well, dropped transfer of this morning was in a rush and late for work but told them its leaking and the back output shaft was lose and fix it, Ill be back in the arvo. Got a call lunch time saying its all done.

The leak was from the counter shaft "O" ring apparently it was pinched going back in and so there was space for oil to get passed and caused it to leak. The owner of the business then said it was actually one of his colleagues who rebuilt it, blame away but I was a little disappointed that he didn't do it originally cos he is a fairly good bloke. Anyway the shaft with the play well Im told there was a cir clip that retains one of the bearings with the kit and it was a little smaller than the other which looks like it was causing it to have just enough to move, so they put in a thicker cir clip. But you can tell its come apart again and the shaft has no movement at all which is good and he said that there was no mysteries at to why the two problems where there as such that they haven't just pulled it apart and put it back together. So Ill put it all back in and get it going and hopefully its no more leaks. Other wise they got it done before the weekend for me and there was no heated words exchanged.... Good outcome well Ill tell you once Im driving it again

Nice outcome mate, good to see there are some decent people left in the automotive industry

i used gasket goo on mine, pretty simple as bolting together was a tight fit and it just sealed any gaps, tho there was nothing on it when i took it apart, just a paper gasket

what i dont understand is why you have a drum on the back of your transfer???? mine doesnt......

Different year model Sierra's had the drum on the rear of the transfer, but I also have Disc brakes on the rear so i need a drum brake transfer case for park brake.

ohhhhhhhhhhhhhh ok fair enough, explains why i dont have one

but yeah i just used gasket goo to seal the case when i re assembled it using a gasket too - done a fair bit of driving since including a full day of wheeling and no leaks, i left it to cure for 2 days before filling it with oil!