1354 different for auto and manual?

[Zorro]

This is the weirdest problem ever.

I just swapped my old A4LD auto for an M5OD, both 4x4 obviously.

I'm reusing my transfer case since I know for sure it works ... but it won't fit! Everything lines up perfectly, slides on the shaft smoothly ... but there is a tiny gap (maybe 1/16, less than 0.5mm all around) between the TC and transmission cap, no matter how much I tighten the bolts.

I removed the centering pin for testing purposes, and it slides in super smooth until that last millimeter.

I can't see any interference anywhere, no scratch marks. The shaft protrudes less than 10mm whereas the TC is at least 13mm deep, same for the groove all around. Everything measures as if it should fit ... but it doesn't.

The TC that was on the manual trans is identical. Same 1354 model designation, same measurements ... and it did fit.

I've wasted a full day on this crap, lifting and removing the TC every other minute ... any pointer would be appreciated.

 

[CopyKat]

Did you remove the eccess gasket material. Sounds like the bolts you are using are too long. and are bottoming out. try putting washers under the head of the bolt and see if it sucks down more.

Since the A4LD is open to the adapter there is a gasket that is required between the tail housing and t-case. The M5OD is closed off to the tail housing and personally a gasket is not required.

 

[Zorro]

I'm using the bolts off the manual t-case. And they are really tightening. When they're really tight, I can see the bolt eyes are touching ... but not between the bolts!
And when I push it on the shaft manually, I can really feel it stopping a mm early.

I hear ya on the unneccesary gasket. I'll remove it and see what gives.

 

[CopyKat]

When they're really tight, I can see the bolt eyes are touching ... but not between the bolts!

You lost me there. If I understand that correct you rear flange on the trans is warped and the case is not sitting flat. It's touching the ears at the bolt's but the space inbetween the bolts has a gap at the mid point.

If that's the case you'll need to find out if the trans adapter is flat. A steel ruler will tell you this.

Or you have alot of RTV at the bottom of the blind holes in the t-case.

Run a bolt into one of the T-case holes and measure the distance from the head to the t-case housing. This should be less than the flange on the trans.

 

[Zorro]

the bolt holes are open anyways, so they can't be too long

You got that right, if I tighten the bolts like a 500lbs gorilla would, it will warp the flange yet not make continuous contact.

I removed the old seal and got a new one ... it looks to be better now for some odd reason.

Fingers crossed it works fine this time.

edit - well, I feel like an idiot now ... it was just the old gasket messing up the contact surface. I removed it, got me a new gasket for a coupel bucks ... and it bolted up smoothly.

 

[CopyKat]

edit - well, I feel like an idiot now ... it was just the old gasket messing up the contact surface. I removed it, got me a new gasket for a coupel bucks ... and it bolted up smoothly.

 

[Jspafford]

I've always just used RTV on that particular flange and it's always held up.

When I used the gasket, it leaked.

 

[CopyKat]

When I used the gasket, it leaked.

You still need some RTV to close up the drain groove. Not sure if it's there for the A4LD

 

[rickcdewitt]

i left it open so you can tell how much the tranny and transfer case are leaking.

 

[Zorro]

I have learned to not plug drains or vents that were supposed to be there in the first place ... left it open.

 

[F150hybred]

The A4LD is sealed between the trans and transfer case. If it were open, the trans fluid would leak out wothout question.