[78machowgn4me]

i have a 1978 dodge power wagon w150 with a 360 4 barrel, 727 trans and np 203 transfer case. when i had the t-case rebulit, the driveline shop used sea 90 wieght gear oil with a friction modifier, their reason being that 10w-30 oil was too thin for california weather. recently i changed the oil and accidentaly put in the 10w-30 with the modifier and it leaked everywhere. after consulting the driveline shop, i put in the 90 wieght gear oil with modifier and it continued to leak. after changing the oil numerous times to try and stop the leakage, the shop found the source of the leak to be the vent, located on the top of the housing. they relocated the vent to the highest point in the engine bay, and it still continues to leak. why would it still be doing this? would there still be residue on the inside of the case, and if so how would i clean it out? this problem frustrates my to no end. any help would be greatly appreciated.

thanks-
foolish kid

 

[Overkill]

are you sure its from the Vent or is it fron the seal between the trans and tcase if it is the vent take off the vent clean out the hose and put on a new vent on the top if it sill does that then you might be overfilling it

 

[78machowgn4me]

im positive that it is the vent, even though it is new. i had the seals replaced and there is no leakage from there. i could tell that it is from the vent because somehow the oil still manages to make its way all the way up to the relocated vent and leaks out of the vent and runs down the hose. im not sure if the oil is foaming or what. and the case is definitely not overfilled, because after the 5th time of draining and refilling i was extra careful in making sure nothing was coming out of the fill hole befire putting the nut back in.

 

[Overkill]

very strange maybe it has a hex on it lolol

 

[78machowgn4me]

im starting to think it couldn't be anything else! im wondering if it could be the modifier that might have cooked onto the inside of the case, and if so is there any way to clean it?

 

[IntenseImages]

first of all smack the crap out of your driveline shop, there is a reason dodge said to use the 30 weight oil.

now an even better question, exactly what vent are you talking about? i have 3 different 203 cases and none of them have a vent on them.

eric

 

[BigJake]

Hmmm....you got me here.

To begin, I can't believe that damn shop put in 90wt. with the mumbo/jumbo BS reason they gave you.

Are you filling it in the right place? That square head nut backed out of its hole...it's impossible to overfill if you're filling it in the right place.

The 203 does not generate a lot of heat...can't believe anything is "cooked" in there.

I would suggest that you drain it again, dump a quart of Rislone or a pint of CD-2 in the case, fill it to proper level with 10W-30, drain it after a few hundred miles, then fill it with 10W-30.

 

[78machowgn4me]

thanks for the suggestions. unfortunately, the shop didn't confirm the type of oil they were goin to use with me, otherwise i would have said no way in hell. the reason that i think something might be cooked inside, is because i used the 10w-30 with the modifier, which probably thinned it out to much. and even now with the 30 wt. in there, after a drive of around 60 miles, the case is damn hot. at least as hot as the transmission i would say. is that about the normal temp, or way over?

 

[Chump]

Could be the case is cooked again. There are several seals in the output housing and an oil pump. There is supposed to be a flat seal at the vent inside the housing. Could be one of the rear bearings on the rear output shaft is on its way to being toast. Use 10W-30 regular engine oil only or synthetic of the same weight.

 

[78machowgn4me]

i didnt know the 203's had an oil pump. is it a possibility that maybe the oil pump got knocked around and repositioned, or maybe got clogged? and if the vent seal was toast, that would cause oil to come up through there vent.....is that logical?

 

[Chump]

I really dont know why you are leaking but my guess would be that there is a seal missing/damaged, it's assembled wrong or one of the rear bearings is bad. Maybe the 90 weight caused some excess pressures? I have never had that problem. I do know that the seal under the vent appears to seal off a part of the housing where the oil pump is as I have replaced this seal when I was doing some preventative maintainence on the case. Relocating the vent isnt the answer...that shop owes you another rebuild or some money back. They should have never installed SAE 90 in the case.

 

[78machowgn4me]

all the bearings and seals are on the output shafts are good because they were the first thing to be replaced after this problem started happening. is it difficult to replace the vent seal? if not, would the local parts store have one or would i have to go to dodge?

 

[Chump]

If all the seals were replaced than i doubt the vent seal is a problem. You would need a service manual to see how the seal is installed and I dont think they are available from Dodge anymore. Their part number is 3894485. local parts stores would not have the seal, maybe a transfer case rebuilder or you have to buy the complete gasket kit for about $60+.

 

[SortaRican]

What is the proper lubricant for an np 208? I was told to use automatic transmission fluid. Should I shoot the guy who told me that, or what?

 

[78machowgn4me]

actually the only seals that were replaced were the front and rear output shafts. approximately what size and shape is the vent seal, and how big is it? it might be sitting in the bag of seals and bearings i picked up to replace the output shaft seals, but i would't recognize it if i saw it.

 

[IntenseImages]

What is the proper lubricant for an np 208? I was told to use automatic transmission fluid. Should I shoot the guy who told me that, or what?

dont shoot him, he was correct

eric

 

[sig sauer]

actually if you are leaking from a vent, your vent should be on the tail end of the transfer case and can't be relocated so if they relocated it: it is wrong.mine leaked from the vent also however this was because i had it at an odd angle, once i mounted the tcase to the tranny the leak stopped, and my father inlaw who has been doing this kind of thing for 50 yrs says to use a 90 weight gear oil with no modifier. he says this will cause less wear on the chain, unless you are running a part time system in the 203 then he says to use 10-30, just his opinion, but i trust him, so get a new vent you can order it from a trannsmision shop, and shoot the shop mechanic that put this together, i bet he forgot to put somthing in right, or messed a seal up.