DIY Transfer case rebuild

captainTeeBag · Oct 12, 2012

Hi guys. Have a small leak from the tailshaft output seal on the transfer case. Ordered the seal from Mitsubishi and was ordered from Japan. I waited 5 weeks only to eventually be told Mitsi don't make them anymore and I'd have to go aftermarket. Does anyone know where to get this seal and also a part number???. I'd rather not pull it apart to get the seal out to match if I can help it as the car will be off the road until sorted

EVO-00X · Oct 12, 2012

Meek Automotive sells a rebuild kit for transfer cases which includes bearings and seals. Much cheaper and quicker than going through Mitsubishi.

EVO-00X · Oct 12, 2012

Heres the link. http://www.meek.com.au/index.php?_a=product&product_id=430

captainTeeBag · Oct 12, 2012

Thanks mate will get in touch with meek. However I don't need the bearings etc so 120 is expensive to get a 15 dollar seal. Id assume they would sell each part seperately?? Price for the rear seal from Mitsi was on$19.00 just don't make em anymore

EVO-00X · Oct 13, 2012

Just to be sure, check the transfer case like this:

http://www.youtube.com/watch?v=7DyxXJ42Vpc&feature=plcp

captainTeeBag · Oct 13, 2012

Thanks mate will have a check

EVO-00X · Oct 13, 2012

If your transfer case checks out OK as per above video with no shaft play, teeth wear etc, then yeah, just do the seals. Ive just put together this list of transfer case rebuild part numbers for you that I have set aside for doing my own rebuild. This will get you out of trouble

. A rear seal on its own should be around $10.
Oh, and underneath the pics is the workshop manual in PDF, for rebuilding your transfer case.

GSR/EVO I-III Transfer case rebuild part numbers

· Koyo LM67048/10 (same part number in other brands) = 31.75mm ID, 59.131 OD, tapered roller bearing [Imperial]

· Koyo 32010 (SKF 32010XQ or NSK 32010XJ) = 50mm ID, 80mm OD, tapered roller bearing [Metric]

· Koyo 32008 (Timken 32008XM) = 40mm ID, 68mm OD, tapered roller bearing [Metric]

· Koyo 32009 (Timken 32009X,) = 45mm ID, 75mm OD, tapered roller bearing [Metric]

· NDK 30-45-6, 30 x 45 x 6mm seal (transfer shaft, input seal) – you can get away with 7mm if you can’t find 6mm. (See my pic of both seals below which are 7mm)

· NOK AH1895E, 32 x 48 x 10mm seal (rear transfer case, driveshaft seal) – you can get away with 7mm if you can’t find 10mm. (see my pic of both seals below which are 7mm)

· 1 x 95mm x 3mm OD o-ring (I think its actually 85mm flacid)

· 1 x 100mm x 3mm OD o-ring (I think its actually 90mm flacid)

Liberoz · Oct 14, 2012

9x outta 10 its leaking from the seal But mostly due to superseeded yoke which mitsu replaced with a slightly different design
seen alot of guys just replace the seal only to find it wears out and leaks again
The revised yoke part will fix this issue for good (unless you have already upgraded the yoke)
The old part number now super seeded
Yoke, Propeller shaft seal MB000408
The revised part number MB111611

(",)

ULS33-RVR-GO · Oct 15, 2012

What's a S/H transfer case (Evo III: 29/27 ratio) worth these days anyway?

captainTeeBag · Oct 16, 2012

I can get a good Evo 3 one for about $300.00 but can someone tell me if it will work properly with the gsr or if not what will need doing?? I'm contemplating buying it and having it altered to suit the gsr if needed so then I have a spare

EVO-00X · Oct 16, 2012

Nope. An Evo 3 transfer case is only specific to an Evo 3 gearbox as it has a 63 tooth front diff crownwheel. It is NOT a compatible bolt on job to GSR which uses a 58 tooth crownwheel or an Evo I or EVO II which us a 64 tooth crownwheel. Front diffs and crownwheels can be swapped over between gearboxes but it will involve fully opening up a gearbox to do the swapover.

I just made this pic up for reference guys. This should help people figure out what ratio transfer case they have.
All the outer casings for GSR, EVO 1 and EVO 2 show up as the same part number in ASA.
So whether you have a GSR, EVO 1 or EVO 2 transfer case it doesnt matter. They are all the same 1.09 ratio (24/22).
JUST DONT USE AN EVO 3 1.074 (29/27 TRANSFER CASE WITH A GSR OR EVO 1/2 DRIVETRAIN!!

RicKii`` · Mar 25, 2013

NDK 30-45-6, 30 x 45 x 6mm seal (transfer shaft, input seal) – you can get away with 7mm if you can’t find 6mm. (See my pic of both seals below which are 7mm)

this seal Rob, can you just purchase it at wholesale bearings or something?

EVO-00X · Mar 25, 2013

Yep for sure.
Here's a copy of an invoice that a mate got some bearings and seals for Wholesale price at a local bearing supplier.
It lists the 2 seals in this attachment and their part numbers too. It may correspond to other suppliers, if not all you need are the dimensions.

EVO-00X · Mar 25, 2013

This should be a tech sticky DIY Transfer Case Rebuild.

RicKii`` · Mar 25, 2013

EVO-00X said:
Yep for sure.
Here's a copy of an invoice that a mate got some bearings and seals for Wholesale price at a local bearing supplier.
It lists the 2 seals in this attachment and their part numbers too. It may correspond to other suppliers, if not all you need are the dimensions.

and the other seal on the gearbox shaft is the same one?

+1 for sticky, i went thru 10+ pages before i found this goldmine!

EVO-00X · Mar 26, 2013

Rickii, here are the 2 seal sizes. Dont worry about the brand, look at the specs in bold red writing that you ask for over the counter.
NDK 30-45-6, 30 x 45 x 6mm seal (transfer shaft, input seal) – you can get away with 7mm if you can’t find 6mm. (See my pic of both seals below which are 7mm)
NOK AH1895E, 32 x 48 x 10mm seal (rear transfer case, driveshaft seal) – you can get away with 7mm if you can’t find 10mm. (see my pic of both seals below which are 7mm)

4piknup · May 24, 2017

TMZ is doing a group buy on hardened shaft yolks to suit the 300m output shafts.

Also in passing, he mentioned he is trying to source material to make better transfer case gears.....

DIY Transfer case rebuild

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