Anybody ever run their transfer case dry?

RumBum · 09-18-06, 01:41 PM

I had a little mishap a few weeks back when I was moving my truck from my garage to my buddy's garage a few miles down the road. I've been rebulilding the truck for about a year and a half and I figured I would drive it the short distance vs. trailering it. About 3 miles down the road the transfer case locked up and I did a 180 doing about 30mph strapped in with a piece of braided nylon boat line for a seat belt (not recommended). After about 5 minutes I was able to move the truck off the road and assess the situation. The t-case was bone dry and I guess the gears seized up. I put fluid in it and drove it the next 2 miles and it seemed fine. I drained all of the new fluid out and didn't see any large chunks of metal. I am wondering what kind of damage I might have done if any.

Has anybody else done anything like this or have an opinion if my t-case is ruined?

I guess the slow t-case drip I had for a little while was bigger than I thought. Idiot move of the month goes to me I think.

Enigma · 09-18-06, 01:59 PM

Yup. Years ago I was 'wheeling up Tin Hat mountain (Powell River, BC), and as I drove over a largish rock I heard a funny sound underneath. Got out and looked (no skid plate on) but didnt notice anything and kept going for the rest of the day. On the drive home back down the logging road, it seemed to be getting a lot louder inside the cab. So we stopped at the pavement to unlock the hubs and have another look underneath. There is a large hole in the tcase, hence the loud noise 'cuz no oil. A prudent person might have towed it from that point, but I figured screw it, we had been driving like that for most of the day so onward and home we went.
I took out the tcase later, had the hole welded 'whole', and put it back in (with new oil of course). It never even seemed to notice. I cant recall how long that tcase was in after that, because at that time of life I was replacing tcases on a fairly regular basis (19 years old, heavy foot, chevy 350).

1973Guppie · 09-18-06, 10:14 PM

I at one point banged the drain plug and lost it completely. Things started getting VERY loud halfway home and I realized I lost my plug. Filled it up and drove it like this for some time before sending out the TC to be rebuild. Guy who did the rebuild said he couldn't believe it was still running as I guess things were prett burned up inside. I always now have a nervous tick of checking my drain plugs.

If it runs and it ain't broken, drive it. When it breaks, fix it.

Noah

Martian · 09-19-06, 12:35 AM

I did this Saturday on the way home from purchasing my FJ40! Was driving down the highway at 50 mph when I started hearing a whining sound coming from the tcase shift lever. Pulled off the road and saw oil spewed all over the underside of my rig. I had to drive 1/2 mile to get off the highway to a safer spot to get a better look. Decided to call AAA to get me the rest of the way home (I will ALWAYS have my AAA membership!!!)

I don't have much experience with a wrench but I've ordered the Factory Service Manuals, can follow instructions, and can ask questions if I'm unsure of things.

We'll see how it goes. I'd rather dive into a rebuild and resolve any problems in the garage rather than wonder if it's going to break down on me in the woods.

bad_religion_au · 09-19-06, 02:36 AM

done it 3 times now. first time was a leak, and when i finally drained it nothing came out. had no idea.

second time i chipped the case on a rock, lost the diff oil, drove it 150 miles home before it died around the corner (gearswere melted together)

third time some pr!ck pulled my drain plug while i was parked outside my friends place (her ex was the pr!ck). and i drove 60 miles before the noise got to me and i realised.

limped it home with the front diff filler plug in the drain hole

Martian · 09-19-06, 09:22 AM

Quote:

Originally Posted by bad_religion_au

done it 3 times now.

Each time did you rebuild the transfer case or did you replace it?

RumBum · 09-21-06, 08:47 AM

I just drove the truck for the first time in a few weeks. I had to re-tap the drain plug since the old one was stripped and leaking fluid (my problem). There is a whine/squeel coming from the transfer case every once in a while. I don't know if it still lubing up some of the bearings and gears, or if some of the bearings are shot. I've only driven it around the block a few times in LO and HI gears. I don't know if the sound will go away or if I'm gonna have to rebuild. It seems to happen more when the truck is rolling (5 mph+) in gear with my foot on the clutch. It will happen everyonce in a while not moving with my foot on the clutch as well. Any of you guys that have run yours dry had similar issues afterward? Did they 'work themselves out'? I'm think I know what needs to be done, but I would rather not have to do it.

bad_religion_au · 09-21-06, 11:51 AM

Quote:

Originally Posted by Martian

Each time did you rebuild the transfer case or did you replace it?

first and second time was the same case in the 45. a year apart. first time just topped up fluid and kept driving it.

after the second time, it was replacement (As the gears melted)

third time was in my 40. drove it for another 6 months after by just adding gear oil, and am in the process of replacing it now, only because i got a good deal on a split case (and i want lower low range gears down the road, and no one makes lower gear sets for the single piece case).

bad_religion_au · 09-21-06, 11:53 AM

Quote:

Originally Posted by RumBum

. It seems to happen more when the truck is rolling (5 mph+) in gear with my foot on the clutch. It will happen everyonce in a while not moving with my foot on the clutch as well.

if your not moving, with your foot on the clutch it won't be the T case... i'd put money on it being the clutch throwout bearing. sounds exactly like mine did

RumBum · 09-21-06, 01:30 PM

Quote:

Originally Posted by bad_religion_au

i'd put money on it being the clutch throwout bearing.

3 questions:

A. Is the clutch throwout bearing the same as the 'release bearing' in the service manual?

B. Does that in any way shape or form have anything to do with running the t-case run dry?

C. It shouldn't squeal unless the clutch is pushed in if it is that throwout bearing, right?

Thanks. I am really just trying to rule the t-case out b/c I don't want to be cruising down the road and have it lock up again b/c of worn bearings or something else broken. The 180 in a lifted 40 series was anything but fun and I really don't want to do it again. I don't mind a slow roll in the mountains, but not an abrupt turn around.

bad_religion_au · 09-21-06, 09:01 PM

Quote:

Originally Posted by RumBum

3 questions:

A. Is the clutch throwout bearing the same as the 'release bearing' in the service manual?

B. Does that in any way shape or form have anything to do with running the t-case run dry?

C. It shouldn't squeal unless the clutch is pushed in if it is that throwout bearing, right?

Thanks. I am really just trying to rule the t-case out b/c I don't want to be cruising down the road and have it lock up again b/c of worn bearings or something else broken. The 180 in a lifted 40 series was anything but fun and I really don't want to do it again. I don't mind a slow roll in the mountains, but not an abrupt turn around.

a. no idea

b. no

c. mine squeeled while driving sometimes as well. mine was well and truely siezed tho

i can't see how it could be the T case if it does it stationary

gladly · 09-22-06, 12:32 AM

a/ yes
b/no
c/right

but the throwout (release) bearing could squeal for a long time before anything ever came of it, mine squealed when the PO bought it, squealed when I bought it, and three years later, it squeals. at least six years of fairly regular use
you could either:
1/ top it up, keep an eye on the level, and don't worry about it too much,
or if you have lots of time and money (and ambition)
2/ tear everything apart, rebuild, and know for sure that it's OK.
I'll go with option 1

RumBum · 09-25-06, 12:11 PM

Quote:

Originally Posted by gladly

you could either:
1/ top it up, keep an eye on the level, and don't worry about it too much,
or if you have lots of time and money (and ambition)
2/ tear everything apart, rebuild, and know for sure that it's OK.
I'll go with option 1

Option 1 seems like the ticket. The squeal sounds like it's from the transfer case, but it usually squeals as I start to push the clutch in. I've also been told the bearings in the t-case may have been destroyed. We'll see over time I guess....