Transfer case rebuild questions

I tore down my D18 transfer case yesterday for rebuild/reseal(it had several leaky areas) as part of my ongoing project(see "Finally got going on my 60 build" in the build forum, insert link function not working for me ). Surprisingly, everything looks pretty good inside. The only questionable areas of wear are the outer races of the timkens scheduled for replacement. The previous owner must have been in it since there was semi-fresh orange RTV all over it. I have a couple of questions though.

First, the intermediate shaft has a groove and o-ring on the rear portion where it mates to the case. The front portion does not. This was the source of one of the leaks that it had. Should I duplicate the groove and o-ring on the front side? I have the capability to machine the groove. I guess I'm looking for confirmation that this area of the shaft is not an unusually high stress area. I'd hate to cut the groove and have the shaft snap there when I'm out wheeling.

Also, I have the capability of powdercoating the case and exterior parts. I know that powdercoat can hold some additional heat in. Does anybody think the amount of heat held would be detrimental?

Opinions, thoughts and comments appreciated.

Thanks fellas.

 

As far as the o-ring on the front side of the intermediate shaft, I don't think you'll get the shaft through the needle bearings or thrust washers with an o-ring on there. I just put RTV on the outside where the shaft and case are flush. So far no leaks there.

 

In the front case bore for the intermediate shaft I smear a very thin coat of sealer just before the shaft is driven through. I put just a touch in the area where the o ring on the shaft too. This seems to eliminate leaks between the shaft and case. The reason I put some by the o ring is ive had too many o rings get damaged as the shaft was driven into the case and still leak.

As far as powder coating the case goes, I do t see it being worse than a heavy coat of paint or 50-60 years of baked on grease.

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Thanks for the replies.

I will use some Yamabond to seal the intermediate shaft. Speaking of which, upon closer inspection, the shaft shows some very slight roller pounding. The best I can measure shows about .0004" deviation. I think I'm gonna replace it along with the rollers and thrust washers.

I'm guess I'm gonna have to fire up the powder coat oven soon....

 

Can anyone give me the Omix-Ada part number for the 1 1/4" intermediate shaft kit. Their website doesn't give much info up.

 

I'd recommend getting the intermediate shaft from Novak as it is much better quality. many of the offshore units are not heat treated properly and wear out quickly.


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X2. Stay away from Omix drivetrain parts.

 

+1 for the novak kit.

 

Not sure what Novak's kit costs, but, when I replaced my intermediate shaft and bearings, the kit from Herm was around $45, I've driven it quite a bit and haven't noticed the transfer case noise getting any louder. Guess it's holding up ok.

 

Doesn't Herm sell the Novak shaft with his kits?

I think the main issue is the hardness of the intermediate shaft. I presume that all the remaining parts are commodity stuff.

 

I'm not sure if he uses the Novak shaft or not. I looked at both websites and he has them beat by better than half the price. ???

 

You can call Herm and ask him. He has a reputation for being very helpful on the phone.

 

I got my kit from Herm also. He did say it was a hardened shaft but didn't say if it was a Novak shaft. It does have the o-ring groove if that means anything.

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Thanks for the tips. I saw the Novak kit, but my budget is not cooperating at this point. I'm going to call Herm tomorrow. Looking at his website, I think he's going to become my new best friend .

I finished up the powdercoating today. I did the xfer and the driveshafts while I was at it. I'll post up pics in my build thread in the next couple of days. Assembly with start this weekend(minus the intermediate shaft until it arrives).

 

I think Herm is having his own made. He was selling the Novak shaft but not sure if he still is. I know Herm has a Rockwell hardness tester he's been playing with to test various parts. Herm makes lots of quality stuff but a lot is sent overseas for manufacture. Doesn't make it inferior by any means as he stays on top of the quality. I just don't like sending my money overseas when there are quality options made here keeping our own folks employed. Jmo of course.


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