Outer Limits 4x4 Board

hey every one has anyone had the problem of the gearbox pumping oil into the transfer case? this is in a troopie any help would be great thanks

Yep very commen problem.Itermediate seal between G/box and tranfer leaking.There is a easy fix.Go to any decent 4x4 store parts place and they will have a kit that consists of 2 new filler plugs with a brass out let tapped into them and a piece of hose and clamps to run between the pair and via gravity oil will level out.You can make it up yourself if you have drills and a tap.Great easy fix untill you have another reason to split the cases.Ive personally made this up for atleast 50 of them and it works a treat.Just seen your from Penrith.Go see the guys at Cheapa Auto spares,they should be able to help you out.
PS. Make sure your breathers are not blocked.

sounds like a good idea thanks heaps for that ill get onto it in the morning cheers .

AUSCRUZER wrote:Yep very commen problem.Itermediate seal between G/box and tranfer leaking.There is a easy fix.Go to any decent 4x4 store parts place and they will have a kit that consists of 2 new filler plugs with a brass out let tapped into them and a piece of hose and clamps to run between the pair and via gravity oil will level out.You can make it up yourself if you have drills and a tap.Great easy fix untill you have another reason to split the cases.Ive personally made this up for atleast 50 of them and it works a treat.Just seen your from Penrith.Go see the guys at Cheapa Auto spares,they should be able to help you out.
PS. Make sure your breathers are not blocked.

Bzzzzt wrong

that is an easy fix for when it is pumping oil forwards resulting in an empty transfer case. Since the gearbox level is higher than the transfer filler level it automatically goes back to the correct levels.

Now when the reverse happens, that same crossover tube doesn't help at all, since the seal is now allowing oil to move to the transfer, overfilling it and blowing the output seals. Because the gearbox filler is higher than the transfer all that happens by fitting the pipe is to still have an over full transfer and an under full gearbox. And you still have an oil leak.

Hilux turbo - if the oil is winding backwards to the transfer i'm sorry but the only proper fix is to pull down the transfer and replace the seal. It is possible by the backyarder if you're handy with spanners and have a manual.

hey rockcrawler , i dont mind having a go at pulling it apart do you know if its like a lux and you can just unbolt the transfer off the back of the box or do you have to disasemble the transfer ?

Are you sure its pumping it from the gearbox to the Tcase not the other way around? Ive never seen them go this way before in the cruisers.

hi ruff yeah i took the filler plug out of the t case and about 2 litres drained out and i pumped it back into the gear box

Interested to know how you found out you had a problem?

Bugger should have done a refresh!

Ok I have a leaking front output seal, is this easy to replace?
Could it be an indication of the above problem?

hiluxturbo2.4 wrote:hey rockcrawler , i dont mind having a go at pulling it apart do you know if its like a lux and you can just unbolt the transfer off the back of the box or do you have to disasemble the transfer ?

Unfortunately not. It will be a split case that is built onto the back of the gearbox. You'll have to disassemble it off the box in the car or remove the box and transfer from the car and do it on the bench (much easier).

Yeah you might find the seal might be hard in the transfer causing it to leak but the problem might also be that the input gear on the transfer has worn on the splines and has become loose on the output shaft ,this can damage the oring that seals the splines and cause the same problem.

Guess I may have to get someone to look at it, would have a look myself but don't really have a good place to work on it.

RUFF wrote:Are you sure its pumping it from the gearbox to the Tcase not the other way around? Ive never seen them go this way before in the cruisers.

i found out when i stopped driving to find oil pissing out all the output shafts and out the PTO output.

when i took out the filler plug on the Tcase about 1.5 litres of oil came out, when i refilled the gearbox it took about three or four litres of oil and was making a terrible whining noise before i filled it.

So barring anything else i can think of the oil was being pumped front to back

RUFF wrote:Are you sure its pumping it from the gearbox to the Tcase not the other way around? Ive never seen them go this way before in the cruisers.

I have only seen it once on a fj60 l/c ... when i pulled the t/case apart i found the o-ring on the idler shaft was leaking and allowing the g-box oil to over flow the t/case ...... but when you have it apart replace all the seals .... and check the g-box out put shaft for wear ... if it is worn you can buy a longer gear that replaces the pto gear and drives off the full length ... i stock the new gear if you need one ....
(but normly on l/c the oil over fills the the g-box and emptys the t/c and i have fited level pipes to all my l/c )