Transfer Case - Oil Leak at Transmission Joint Area
90chrysler15SUBJECT: Transmission/Transfer Case Output/Input Seal Leak Diagnosis
NO.: 21-21-90
GROUP: TRANSMISSION
DATE: Nov. 19, 1990
MODELS:
1990 (AN) DODGE DAKOTA 4WD
SYMPTOM/CONDITION:
Some 1990 4WD Dakotas with NPG 231 transfer case with a serial number (build date) between 6-3-89 and 12-15-89 may exhibit an oil leak at the transmission to transfer case joint area.
On vehicles equipped with the A-500 transmission, the leak may appear at the "weep hole" on vehicles equipped with the NP 2500 manual transmission, the leak may appear at the transmission/transfer case joint.
Leakage in this area may be the result of a finish problem on the transmission seal contact surface on the 231 transfer case input gear.
DIAGNOSIS:
Raise the vehicle. Inspect the transmission/transfer case joint area or "weep" hole for indications of leakage. If leakage is evident, check the transfer case serial number (build date). If the serial number is between 6-3-89 and 12-15-89, perform the following repair procedure. If the transfer case serial number is before or after the above dates, repair leaks as necessary.
PART REQUIRED
1 - Dye, Automatic Transmission (1 oz.) PN 04549631
1 - Dye, Manual Transmission (1 oz.) PN 04549629
1 - Input Gear PN 53006085
1 - Seal, Transmission output PN 04269956
1 - Seal, Transfer Case Input PN 04167929
REPAIR PROCEDURE
This repair involves inspecting suspect leak area with ultraviolet light (black light) and replacing the transfer case input gear if required.
1. Install 1 ounce of transmission dye into the transmission. Be sure on vehicles equipped with the A-500 transmission that the weep hole is not plugged with dirt or RTV.
NOTE: IF THE MANUAL TRANSMISSION LUBRICANT HAS BEEN CHANGED TO ATF, USE THE AUTOMATIC TRANSMISSION DYE PN 04549631.
2. Road test the vehicle to ensure the dye has thoroughly mixed with the transmission fluid and the transmission has reached normal operating temperature.
3. Raise the vehicle.
4. Aim black light, tool C-4555, or an equivalent at the transmission/transfer case joint area or "weep" hole. When a leak is present, the black light will cause the dye to glow a bright fluorescent yellow/green.
5. If the black light indicates a leak at the transmission/transfer case, joint area or "weep" hole continue this repair procedure. If the black light indicates the joint area or "weep" hole is not leaking, locate and repair the leak as outlined in the 1990 Dakota Rear Wheel Drive Service Manual, Publication number 81-370- 0110.
6. Remove the transfer case as outlined in the 1990 Dakota Rear Wheel Drive Service Manual, Publication number 81-370-0110.
7. Disassemble the transfer case as outlined in the Service Manual.
8. Install a new input gear PN 53006085.
9. Assemble the transfer case, being sure to install a new input shaft seal PN 04167929.
10. Remove the transmission output shaft seal. Install new output shaft seal PN 04269956.
11. Install the transfer case.
NOTE: DO NOT USE RTV AT THE TRANSMISSION/TRANSFER CASE JOINT OR "WEEP" HOLE.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No. 21-03-01-90 .......... 0.5 Hrs.
Transmission Leak Check
21-03-01-91 .......... 4.7 Hrs.
Replace Transfer Case Input Gear And Transmission Output Shaft Seal
FAILURE CODE: 71 - Oil leak