DD Machine doubler leak

[2FFords]

Hey Gents,


Is there a secrete to sealing up the doubler against leaks? I have tried copper rtv twice, and Honda-bond. I still have a leak. Im trying to make a run in Panament Valley CA in 3 weeks and I dont want to give the "Enviro-Terrorists" another reason to hate our sport....

Thanks

 

[4x4junkie]

Where is it leaking from? (block-off plate? breather? somewhere else?)

 

[2FFords]

It seems to be comming from the two adapter plates. I put a ton of sealant on the inside too. I also filled the non used bolt holes on the inside of the assembly with honda bond when I painted the seam of the plates. I'm at a loss.....

 

[crawlin91]

duffy recommends using Great Stuff sealant. there are good informative threads on this doubler kit over on RRORC.com and pirate4x4.com

 

[4x4junkie]

Yeah I've found sealing it up completely can be a little tricky (took me three tries to get mine to not leak anymore).


Try using an actual t-case gasket (along with the RTV) between the rear case and the rear adapter plate (this is what it took to get mine to not leak there anymore).
RTV alone seems to be fine between the two plates themselves, however make sure the socket screws holding them together are good & tight.

The 2nd time I had to take mine apart was due to a real slow leak from between the front (doubler) case and the main adapter plate of the kit along the top (I also was getting occasional belching of fluid out the breather tube which I had relocated to the top). Upon disassembly I found two of the (taper head) socket bolts holding the doubler plate to the front case had become loose, not sure why, so I cleaned everything up good and then reassembled it, torquing all the bolts down real good this time (also I made a little baffle using the tin case off an old 9V battery to go over the hole inside for the breather vent). So far this time it looks like I finally nailed it.


Other things I did from the beginning was run a bead of RTV sealant inside the case along the joint where the block-off plates are welded at the end, as well as screwing down the block off plates into the case itself (I screwed them down because I "JB-Welded" the plates in, didn't have equipment on hand to actually weld the aluminum). I also made sure all the gaps between the plates and the case were filled with "weld" as well, then smoothed everything down so the doubler plate would seal correctly against it. No leaks have occurred at this location on mine.

Hopefully some of that helps.

 

[bigblockford79]

I had an impossible leak between my 208 and clocking ring I could never get to stop leaking even with "the right stuff" it leaked bad. I finally got it to seal by making a gasket from a cut it yourself cork material sheet and applying form-a-gasket sealant to both sides when I assembled it. It never leaked after that.

 

[2FFords]

Alright that helps a lot. Thanks guys I appriciate all the info. Gonna get at it this weekend along with another tranny change. Hopefully I can make it all happen by next month. I have a run to get to.