84 Transfer Case Leak

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Oct 13, 2009 | 11:38 AM

MRStace84

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84 Transfer Case Leak

I've got an '84 F150 4x4. I forget the exact model, but the transfer case is a New Process with the Aluminum housing. The case is a bad cast, it's really porse, and oil just leaks through the case. I was just wondering if anyone has had a similar problems, and had any luck with trying to seal the case somehow? Several years ago we tried some epoxy, but either we didn't get it in the right spot, or it didn't help very much.

Thanks,

Oct 13, 2009 | 06:49 PM

Eddiec1564

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From: Arcadia, Fla

Its probly a NP208 xfer case. Where is the leak from? On my 84 F250 the case gasket started leaking on me. As I didn't want to take it down and apart, I cleaned off the area after I drained the xfer case with brake clean, then I used that "import grey" rtv and put a good layer up into the seam. So-far 5+years later no leaks!

Oct 13, 2009 | 07:21 PM

MRStace84

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Yeah, it's the NP208, that rang a bell as soon as I read it. It leaking on the bottom, on the back half. It's not the seam, the oil comes right through the casing, I may try to drain it and clean it, and try some good RTV on it.

Thanks.

Oct 14, 2009 | 12:47 AM

bghnkinf250

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From: Bay Area, Unfortunately

You might wan to get another housing for peace of mind. It sounds like you have been chasing this problem for a little bit. They are relatively cheap.

Oct 14, 2009 | 06:45 AM

MRStace84

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At one point in time, we tried to find another housing, but didn't have much luck. Can you get them any other place besides a salvage yard? Does anyone sell them new?

Thanks

Oct 14, 2009 | 02:36 PM

Eddiec1564

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From: Arcadia, Fla

I only found them in the rip-off yards(they want $300 for a xfercase!) Then one day one of the yards had a sale, too bad I didn't find a np-208 at that time but I did grab the np435/BW-135? set for $150. Only to find I should of grabbed the drive shaft! The np208 has the slip yoke and the Bw135? is fixed yoke.

Is there a crack or just a porus hole leak? If there is a crack, you may want to drill stop holes on each end of the crack to stop it running. If its just a porus hole leak, I seen others drill it out and put in a plug. If you are going to drill, just leave the oil in the case and it will flush out the drillings when you drill through and go SLOWLY while drilling.

Oct 14, 2009 | 05:57 PM

bghnkinf250

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From: Bay Area, Unfortunately

I would also check craigslist and such. I am not sure, but how does a pourous casting affect the strength of the case, or does it even do so (although the truck has been around for about 25 years, so probably not all that much).