th350/np205 leaking

HotRodpayton · Jan 16, 2010

Just like it says, its bad, real bad. I pulled the case and adapter, put new seals in( the correct way) put a new o-ring on the t-case shaft, sealed the inside of the coupler with some silicone between the shafts. I put the best gasket maker made on each side. I had one bolt that the threads seamed to be stripped on the adapter to the case. I put a longer bolt in, and it tightened up pretty good, but I didn't really crank on, trying not to cause further damage. I don't have trans fluid getting in the t-case, but somewhere unknown (I've looked everywhere) It is pouring fluid just sitting in the shop. My buggy is tight, and I can't see every inch of the adapter, any suggestions, could it be the bolt that not cranked down on??? Should I put a heli core in???? Need some help, it's driving me nuts.

jscarbro · Jan 17, 2010

double check and make sure there isnt a hairline crack where the adapter and tranny mate. i had 2or3 develop hairline cracks at times when the bolts would vibe loose.then stupid me would not wanna fix it when it would leak then once slack gets in there thats when cracks start. but if u got 1 stripped u need to helicoil it cause all that woopow it needs every bolt in it

DirtyEC · Jan 17, 2010

I had the same kind of mysterious leak last yea this time with my TH350/NP205. It was a crack on top of the trans. I couldn't see it, but when I pulled the 205, a rather large chunk of the aluminum case came with it.

I pulled the trans apart, and had the case tig welded. I also had to helicoil all 4 bolt holes that mount to the adapter. It's been OK for over a year now.

HotRodpayton · Jan 17, 2010

Thanks guys, I thought the adapter could be cracked. It's been broke and rewelded. I am going to try a helicoil first, no change I'll prolly get a new adapter.

Woodlee · Jan 17, 2010

Make sure the tranny isn't cracked.

Jhouser · Jan 17, 2010

I had one do the same thing and it was the transmission case. It was cracked it broke off one of the top ears. Thats where i would start good luck its a pain. The buggy looks great. :dblthumb:

HotRodpayton · Jan 17, 2010

Very well could be the case. If it is, I'll prolly just add oil for now as needed. Thanks for the advice and comments. I'm gonna do what I can without removing the t-case again. I have to take alot apart. May run it for a time or two then fix it. I'm 100% sure what I've done so far is not right. I def. agree with you guys, it's something I can't see so easily.

kid rok · Jan 17, 2010

Are you leaking transfluid or T-case fluid?
If your leaking trans fluid I would fix it, because it's very flammable especially under pressure.
If it's just T-case oil run the hell out of it.

badreligion_13 · Jan 17, 2010

Further, if the case is cracked, which is a VERY strong possibility your next ride may end very quickly..

HotRodpayton · Jan 18, 2010

Trans fluid is very flammable. It's not t-case oil for sure. I was transfering trans fluid to the t-case. Now thats fixed. It may be the adapter, stated before it has been broke. It may be cracked or warped from the repair. I sure would hate to burn my new buggy up. Plus I hate when my stuff ain't acting right. I'm going to get some dye and a light, clean it up really good and try to find it that way. Anybody done that before?

s10me · Jan 18, 2010

kid rok said:
Are you leaking transfluid or T-case fluid?
If your leaking trans fluid I would fix it, because it's very flammable especially under pressure.
If it's just T-case oil run the hell out of it.

nothing like taking a park owner for a ride and set his ass on fire!