Built Transfer Case?

[Slow99x]

I have a 99 GSX with a few mods and within a month I have gone through two transfer cases. I have not been abusive to the car (launching) and this is the second time a T-case has failed. I did some research on this site about the T-case recall but it does not seem to cover my car. I need to find out if there is a T-case upgrade like the tranny upgrades so that I will not have this problem anymore. I would appreciate any advice on the matter or even better, shop info. I'm only shooting for 11.50s but I don't need to be replacing these T-cases more often than engine oil.

 

[MNGSX]

there is'nt too much to them.

Just two beveled gears which need to be shimmed properly and properly lubricated. There is'nt really anything to build up. If they get run dry they just snowball into a POS and lockup. Properly clearanced and lubed gears are the only trick... It's easier to set one of those up than a gearset in a RWD rear end...

I'd get a case, rebuild parts, a dsm manual and rebuild one carefully then put it in.. Any used one and you don't know what is inside.

 

[Slow99x]

What was the update provided by the recall and does it stop the leaking?

 

[Defiant]

When the output stub has its splines machined into it, there's a through hole. The factory seals this hole with a brass or bronze plug. It leaks. The seal around the outside of the output shaft can also leak. The thing only holds a half-pint of grease, so it doesn't take much of a leak to run it dry. I'm a bit surprised that in all this time no one's come up with a replacement cover like the old VW Formula Vee sumps that added a half-quart to the capacity. The original recall, as I understand it, was for weeping of the plug and replacement of the shaft and inspection of the case, and if any case/bearing damage was found, replacement of the entire assembly. It also seems that Chrysler is more amenable to replacing than Mitsubishi is, from what I've read on here.

I'm also surprised the manufacturer hasn't just poured some damned silastic inside the output shaft to seal the idiotic plug from the inside.

Please advise me of any errors I've made.

 

[MNGSX]

Good idea about sealing the shaft plug with a pourable sealant..

 

[Jeff_Jeske]

I have a 99 GSX with a few mods and within a month I have gone through two transfer cases. I have not been abusive to the car (launching) and this is the second time a T-case has failed. I did some research on this site about the T-case recall but it does not seem to cover my car. I need to find out if there is a T-case upgrade like the tranny upgrades so that I will not have this problem anymore. I would appreciate any advice on the matter or even better, shop info. I'm only shooting for 11.50s but I don't need to be replacing these T-cases more often than engine oil.

What have you done to destroy them???

Well I just put a 95 shep tranny and transfer case into my car. So I have a 98 transfercase in perfect condition if you need another one. I am amazed that you found two 97-99 xfer cases to begin with. They are kind of rare.

Hopefully you are not running a mismatched transfer case and tranny. The 95-96 are not compatible with the 97-99.

FYI - These days most people are running heavy duty redline shockproof in the xfer case.

 

[MNGSX]

I have'nt had a problem with my 96 case.. Maybe the later ones are more leak prone?

 

[Slow99x]

What have you done to destroy them???

Well I just put a 95 shep tranny and transfer case into my car. So I have a 98 transfercase in perfect condition if you need another one. I am amazed that you found two 97-99 xfer cases to begin with. They are kind of rare.

Hopefully you are not running a mismatched transfer case and tranny. The 95-96 are not compatible with the 97-99.

FYI - These days most people are running heavy duty redline shockproof in the xfer case.

I haven't done anything abusive to them like launching. I was under the impression that a 23 spline T-case is a 23 spline T-case and I was unaware of any differences throughout the years.

 

[Syndicate13]

I haven't done anything abusive to them like launching. I was under the impression that a 23 spline T-case is a 23 spline T-case and I was unaware of any differences throughout the years.

That's because there isn't any difference in them. Someone told him this and he chose to believe it. Any xfer case after the switchover date in 92 is compatible with any tranny also built after that date. They only went up one spline count though, there is no difference other than that.

 

[Jeff_Jeske]

Its funny you should say that.....because I had believed the same thing....but both TRE and SHEP told me there was a change in the tranny in 97. The 97+ tranny requires a 97+ transfer case. The 95-96 can use any 23 spline xfer case EXCEPT 97-99.

The rear ends 95-99 are all the same but the trannies and transfer cases are different.

The 1st gear ratio is the same. You can use a 97-99 trans if you use the 97-99 t.case.

Here is another nice link to tranny matching:

http://www.dsmtuners.com/forums/showthread.php?t=87846

I actually have a 92 23 spline transfer case on my 95 tranny in my 98 GSX.

If you didn't put a 97+ xfer case on your 97+ tranny that is why the thing is taking a crap. If you need one.....give me a shout!

FYI - I replaced both trasfer case seals with new seals from NAPA. They appear to be just fine because I dont have any leaks at all.

 

[twenty5psi]

Its funny you should say that.....because I had believed the same thing....but both TRE and SHEP told me there was a change in the tranny in 97. The 97+ tranny requires a 97+ transfer case. The 95-96 can use any 23 spline xfer case EXCEPT 97-99.

The rear ends 95-99 are all the same but the trannies and transfer cases are different.



Here is another nice link to tranny matching:

http://www.dsmtuners.com/forums/showthread.php?t=87846

I actually have a 92 23 spline transfer case on my 95 tranny in my 98 GSX.

If you didn't put a 97+ xfer case on your 97+ tranny that is why the thing is taking a crap. If you need one.....give me a shout!

FYI - I replaced both trasfer case seals with new seals from NAPA. They appear to be just fine because I dont have any leaks at all.

Im assuming the seal you replaced on your t-case is interchangable with a 90 t-case?..If so how much did it run you and what should I go in and ask for?..I only ask this because napa doesnt even know what a dsm is let alone a t-case seal for a dsm..

 

[98GSX_MTX]

Im assuming the seal you replaced on your t-case is interchangable with a 90 t-case?..If so how much did it run you and what should I go in and ask for?..I only ask this because napa doesnt even know what a dsm is let alone a t-case seal for a dsm..

Napa part numbers follow:

Seal - 12736 cost $11.99
Seal - 11592 cost $4.49

The seal that goes in the xfer case and seals the driveshaft is 12736.

 

[Slow99x]

Does anyone know the actual reason that the T-cases are not compatable with the 97-99 trans? Is it gear ratios? Is it fitment?

 

[91TSiAWD_Mark]

That's because there isn't any difference in them. Someone told him this and he chose to believe it. Any xfer case after the switchover date in 92 is compatible with any tranny also built after that date. They only went up one spline count though, there is no difference other than that.

It was actually in 91 sometime. My 91 has a 23 spline case that matches my 92.

 

[98GSX_MTX]

Just to be clear there is a difference between the 23 spline pre97 and 23 spline 97 transfer case. To get the specifics just give TRE or SHEP a call and let them explain.

 

[Slow99x]

I talked to Shep and he kindly explained that the 97-99 T-case was geared to match the different gearing in the trans itself. He explained that the final drive is different and using a 91-96 23 spline t-case could damage the trans when used with locking/welded diff or even a 4 spider diff. Since I do not trust another used t-case I had a used t-case sent to him so that he can "convert" it to a 97-99 by using a new gearset and heat treating the gears for more streangth along with some new seals. The whole thing should run about $500.