Transfer Case leaking - bolts stripped

[edthediscoman]

Transfer case bolts are stripped and have been for some time.

Does anyone have a helicoil or some such device size to repair it.

Or should I drill and retap the holes to a bigger size.

Case is leaking and I am going to play in the sand in 2 weeks and need a solution.

I need to know either:

Drill retap size recommended
or
Insert size and drillbit recommended.

Someone has a shop and has done this before.
Thanks
Ed

 

[martinquebec]

iN MY OPINION i would RECOMMEND BOTH ...your choice an elicoil would require to drill anyway if you dont have elicoil near...drill retap and rebolt happy sand play

 

[edthediscoman]

The concern is the bolt size. If I drill/tap is there enough meat and where can I get the next size - as they are long and narrow.

Or If I go Helicoil, is there enough meat and what size is it?

 

[ptschram]

Well, which bolts are they? Bottom cover? 8 * 1.25, IIRC.

I'd helicoil, but I have done so many that I finally got good at installing them.

 

[edthediscoman]

Well, which bolts are they? Bottom cover? 8 * 1.25, IIRC.

I'd helicoil, but I have done so many that I finally got good at installing them.

LMAO...good idea, would have been nice if I had done it myself. Anyway, its been this way for a few years, but its gotten worse, so time to get it fixed.

Bottom cover - yes. I will go that route, run down and get some helicoils that fit, drill to suit.

Thanks PT as always.

 

[ljdiscovery]

you might try a product called White Shepherd. I found it a Kragens. It is a transfer case leak stop. I used it about a month ago for a small but bothersome leak in a seal on my 99 DI. stopped it in about 70 miles of driving over two days. so far so good. Phil

 

[arrowphoto]

you might try a product called White Shepherd. I found it a Kragens. It is a transfer case leak stop. I used it about a month ago for a small but bothersome leak in a seal on my 99 DI. stopped it in about 70 miles of driving over two days. so far so good. Phil

I would fix it, not drop snake oil in it, but that's just me.

Helicoils are the bee's knees.

 

[arrowphoto]

I deleted part of my previous post about Heli's because I described the wrong truck. It wasn't the 2000 Jeep XJ that I bought, it was the 99 that I bought.

That's a side issue. There is plenty of meat on the t-case for a Helicoil because you are only drilling out the threads, not expanding the hole by a wide margin. Drill it, tap it, set the Helicoil in and expand it. Done.

I will also say that you should buy the actual Helicoil kit and not one of the cheap knockoffs. The kit that I bought to fix my blown spark plug threads included the tap and everything that I needed to get it in. The off brands were cheaper and weren't available in a kit with the proper tools to get it installed.

My spark plug kit had the expanding inserts, but I think that newer kits are self expanding threads. Make certain before you install the thing that the threads are the proper size for what you need. Once you screw a bolt in it or expand it you are largely set in stone. If it is wrong you will have to go bolt shopping.

 

[edthediscoman]

I got the helicoils from Autozone, M8-1.25 (Thanks PT). Will install when the outside temp and the car get cooler later tonight and let you know how it goes.

 

[daven5735]

I got the helicoils from Autozone, M8-1.25 (Thanks PT). Will install when the outside temp and the car get cooler later tonight and let you know how it goes.

Ed, how did your install go? Looks like I'm going to have to do the same thing. The bottom cover plate on my transfer case is dripping from each bolt. And they're tight. Funny how thin that 75w-90w gear oil gets when you drive at highway speeds for 600 miles. I like the helicoil idea. I've never used them before so when installing the M8-1.25's, will I have to use smaller diameter bolts? The gasket also looks like paper from the edge. Would Hylomar make for a better reseal? Paul (PT), I would also appreciate you chiming-in, as always.