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06-03-06, 02:19 PM
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#1 (permalink)
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Focus on the Journey
Join Date: Jun 2005
Location: Southern Arizona
Posts: 1,341
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Tranny to Transfer case bypass hose
I've had a couple of request to give more detail on this setup. The hose is a steel braided -08 Parker "Tough Cover". The centerline distance between the fittings is 15" to 15.25". I made two, and they both fit. The short one is currently in place. The fittings are 37 Deg Flared Compression Tube Fitting, Tube X Male Metric For 1/2" Tube, M18 X 1.5 straight Pipe. McMaster-Carr P/N 4545K223 at a cost of $10.17 each (pg 163). The hose with two 90 degree crimp fittings installed plus two steel caps so I can remove the hose without having to remove the adapters was $35. About what you would pay at either MAF ($55) or SOR ($65). This hose is meant to carry hydraulic fluid that is -40 to 212 degrees. The fittings from McMaster-Carr have an outer steel washer with an inner rubber o-ring that seals against the tranny and transfer case housing.
McMaster-Carr
__________________
78 FJ40
ARB's F&R, Rear Disks, DUI HEI, 200 Amp Alt, OME 2.5, 33x10.50, PS, RE8000, Stout Rear Bumper, 4+Plus Sliders/U-Bolt Flip Kit/Tie & Relay Rods/Anti-Inversion Shackles, Dual Tanks, BTB Dash Box, Tuned Ceramic Coated Headers, Extended Axle Vents, BrakeQuip Custom Certified SS Brake & Clutch Flex Lines
ROTW My Yoda| HD Skid Plate| Recovery & Windshield Washer Tanks| Toyota Pulley on GM Pump| Bypass Hose| Vapor Recovery Tank
Last edited by bsevans; 02-21-08 at 04:07 PM.
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06-03-06, 06:03 PM
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#2 (permalink)
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Ball & Claw Club
Join Date: Jan 2006
Location: NEVADA
Posts: 901
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The By pass Hose is cool Thanks for the Post ,
But the Wholey $Jit Look at the skidd plate!!!!
__________________
66 FJ40L Soft Top Done  ,2006 FJ Cruiser 6 speed ! 1978 FJ55 next project,
and use to have a couple others' 1971 FJ40 , 1977 FJ40, 1984 FJ60 , 1994 FZJ80
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06-03-06, 09:15 PM
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#3 (permalink)
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Site Addict
Join Date: Aug 2003
Location: granite falls WA.
Posts: 1,001
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i already did the bypass, but i too thought holly $hit now thats a skid plate.
__________________
76 FJ40 tuned port injected 350 sbc, toy 4sp/tcase, tilt steering columm, full family cage, longs, 35's, ps, 4/w disc, frenched in ant. etc.
Last edited by lone gunman; 06-04-06 at 07:53 AM.
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06-03-06, 09:30 PM
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#4 (permalink)
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250+ Club
Join Date: Oct 2005
Location: MT
Posts: 280
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Ya, you guys missed it. bsevans started a thread on it in the Hardcore forum:
http://forum.ih8mud.com/showthread.php?t=93447
I think I'll eventually purchase one. Great design. There's been a few posts for a group buy purchase to lower the price. Separate shipping to each buyer, no doubt.
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06-04-06, 01:07 PM
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#5 (permalink)
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Site Addict
Join Date: Dec 2005
Posts: 1,355
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For those of us who are ignorant about the purpose of this hose, what are you bypassing with it?
__________________
"The Constitution is not an instrument for the government to restrain the people, it is an instrument for the people to restrain the government lest it come to dominate our lives and interests."
-- Patrick Henry
ΔΤΧ
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06-04-06, 01:18 PM
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#6 (permalink)
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Site Addict
Join Date: Dec 2005
Posts: 1,355
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__________________
"The Constitution is not an instrument for the government to restrain the people, it is an instrument for the people to restrain the government lest it come to dominate our lives and interests."
-- Patrick Henry
ΔΤΧ
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02-08-08, 06:31 AM
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#7 (permalink)
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450,000+ mile club
Join Date: Jun 2005
Location: albany area, ny
Posts: 4,344
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nice bypass...ever think about making them and selling them?
would be nice to see $$$ go to a mudder
Last edited by JohnnyC; 02-08-08 at 06:38 AM.
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02-08-08, 07:57 AM
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#8 (permalink)
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total rice
Join Date: Nov 2004
Location: bring lawyers guns & money
Posts: 2,874
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For as much work as it took sourcing all this stuff and as nice and well-thought out virtually every part of your truck is, why the band-aid?
I realize it's a $6 seal and a little more work than most are willing or able, but why not just fix the problem?
__________________
1975 FJ40 - V8, 4WDB, Saginaw PS, SR, 4" lift w/ 33X12.50X15 BFG MTR's, M8000 ROTW
2007 4 Runner SR5 4WD - stone stock daily driver
TLCA#10793
"Democracies fail when people realize they can vote themselves a check."
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02-08-08, 08:30 AM
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#9 (permalink)
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Focus on the Journey
Join Date: Jun 2005
Location: Southern Arizona
Posts: 1,341
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Quote:
Originally Posted by dgangle
For as much work as it took sourcing all this stuff and as nice and well-thought out virtually every part of your truck is, why the band-aid?
I realize it's a $6 seal and a little more work than most are willing or able, but why not just fix the problem?
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When I pull the tranny and transfer to rebuild them I will. I might add that the bandaid works quite well thank you. I do not see a downside to the bypass hose. A little more work - that's very humerous. Maybe you have a nice shop you can pull your vehicle in to work on. I can not clear the garage door much less jack the vehicle up, so all in vehicle work for the last 23 years has been done in the driveway which is paved with rock. At almost 62, I'm inclined to take the path of least resistance when on my back getting rock bruises.
__________________
78 FJ40
ARB's F&R, Rear Disks, DUI HEI, 200 Amp Alt, OME 2.5, 33x10.50, PS, RE8000, Stout Rear Bumper, 4+Plus Sliders/U-Bolt Flip Kit/Tie & Relay Rods/Anti-Inversion Shackles, Dual Tanks, BTB Dash Box, Tuned Ceramic Coated Headers, Extended Axle Vents, BrakeQuip Custom Certified SS Brake & Clutch Flex Lines
ROTW My Yoda| HD Skid Plate| Recovery & Windshield Washer Tanks| Toyota Pulley on GM Pump| Bypass Hose| Vapor Recovery Tank
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02-08-08, 08:40 AM
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#10 (permalink)
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450,000+ mile club
Join Date: Jun 2005
Location: albany area, ny
Posts: 4,344
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Quote:
Originally Posted by bsevans
I'm inclined to take the path of least resistance.
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x2
did you also have a leak between the transfer and tranny gasket?
if so..........does the bandaid  fix that also?
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02-08-08, 09:05 AM
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#11 (permalink)
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250+ Club
Join Date: Jan 2003
Posts: 443
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I forgot to thank you bsevans for doing all the work on this. I also had a custom hose made which lookes exactly like yours. I just called up the nearest hydraulic hose shop and told them what I wanted, they had it made in a day. Cost me the same as I would've paid at MAF or SOR.
The difference between adding this hose and replacing that $6 seal is more than just a little more work. Even when I do get around to replacing the seal, I'm still going to leave the hose in place as added protection.
I realize it doesn't fix the cause of the problem, but the way I see it, it's cheaper than rebuilding a transfercase. You never know when the seal is going to fail. My seal wasn't leaking the first time I checked the fluid levels, but when i checked last week the tranny was overflowing. The problem is, unless you're crawling down there checking the fluid regularly, you're not going to catch it. It was just luck that I probably hadn't driven more than 50 miles at low speeds, so I doubt any damage had been done. Now that I'm driving more often I feel much safer knowing that at least my transfercase won't run dry.
Last edited by ducktapeguy; 02-08-08 at 09:11 AM.
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02-08-08, 09:28 AM
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#12 (permalink)
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total rice
Join Date: Nov 2004
Location: bring lawyers guns & money
Posts: 2,874
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Quote:
Originally Posted by bsevans
When I pull the tranny and transfer to rebuild them I will. I might add that the bandaid works quite well thank you. I do not see a downside to the bypass hose. A little more work - that's very humerous. Maybe you have a nice shop you can pull your vehicle in to work on. I can not clear the garage door much less jack the vehicle up, so all in vehicle work for the last 23 years has been done in the driveway which is paved with rock. At almost 62, I'm inclined to take the path of least resistance when on my back getting rock bruises.
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I understand completely! No harm no foul. I have the place and tools and actually enjoy doing stuff like that. At least on my own stuff!
__________________
1975 FJ40 - V8, 4WDB, Saginaw PS, SR, 4" lift w/ 33X12.50X15 BFG MTR's, M8000 ROTW
2007 4 Runner SR5 4WD - stone stock daily driver
TLCA#10793
"Democracies fail when people realize they can vote themselves a check."
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02-08-08, 10:40 AM
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#13 (permalink)
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250+ Club
Join Date: Aug 2005
Location: CAPE TOWN
Posts: 558
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Thanx for the post ! Now I can have some peace of mind untill the rebuild
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Theo
105 1HZT I/C
BJ 42 LX 11/83 - 3b H55F P/S 3 wipers and slidin windas
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02-08-08, 10:56 AM
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#14 (permalink)
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What's next?
Join Date: Nov 2006
Location: Podunk, Arizona
Posts: 2,150
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I've been wanting a skid plate like that for some time, and to find out Caid is right in my back yard.
Thanks bsevans
__________________
'69 fj40
CSC#103
A dry heat still cooks a turkey
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02-08-08, 11:02 AM
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#15 (permalink)
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250+ Club
Join Date: Jul 2002
Location: New Hampshire
Posts: 763
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Quote:
Originally Posted by dgangle
For as much work as it took sourcing all this stuff and as nice and well-thought out virtually every part of your truck is, why the band-aid?
I realize it's a $6 seal and a little more work than most are willing or able, but why not just fix the problem?
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I had bought the stuff to make a bypass hose for mine years ago for about $20 from a local hydraulic hose shop. 2 years ago I rebuilt the t-case and changed that seal. About 10k miles later it was leaking again. So I put the hose back on.
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79 FJ40,85 Mustang GT,05 Tacoma,00 4Runner,89 pickup
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02-08-08, 04:14 PM
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#16 (permalink)
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250+ Club
Join Date: Mar 2007
Location: Salem Oregon
Posts: 263
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Which way does the oil tend to go if seal is bad TC or tranny ?
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Royota
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02-08-08, 07:26 PM
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#17 (permalink)
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Focus on the Journey
Join Date: Jun 2005
Location: Southern Arizona
Posts: 1,341
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In a Landcruiser it always pumps from the transfer to the tranny. In a Jeep it is normally the other way around. It pumps from the unit that has the higher pressure to the unit with the lower pressure. The hose helps reduce the pressure differential and lets the excess pumped into the tranny drain back to the transfer case.
__________________
78 FJ40
ARB's F&R, Rear Disks, DUI HEI, 200 Amp Alt, OME 2.5, 33x10.50, PS, RE8000, Stout Rear Bumper, 4+Plus Sliders/U-Bolt Flip Kit/Tie & Relay Rods/Anti-Inversion Shackles, Dual Tanks, BTB Dash Box, Tuned Ceramic Coated Headers, Extended Axle Vents, BrakeQuip Custom Certified SS Brake & Clutch Flex Lines
ROTW My Yoda| HD Skid Plate| Recovery & Windshield Washer Tanks| Toyota Pulley on GM Pump| Bypass Hose| Vapor Recovery Tank
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02-08-08, 09:29 PM
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#18 (permalink)
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250+ Club
Join Date: Sep 2005
Location: Willamette Valley-Oregon
Posts: 468
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Quote:
Originally Posted by bsevans
When I pull the tranny and transfer to rebuild them I will. I might add that the bandaid works quite well thank you. I do not see a downside to the bypass hose. A little more work - that's very humerous. Maybe you have a nice shop you can pull your vehicle in to work on. I can not clear the garage door much less jack the vehicle up, so all in vehicle work for the last 23 years has been done in the driveway which is paved with rock. At almost 62, I'm inclined to take the path of least resistance when on my back getting rock bruises.
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bsevens
You seem to have so many good ideas and info to share with us here on mud so maybe I can return the favor now. I am also having to lay on gravel to work under my 40 for now. Then--- I spied a floor pad that goes under an office chair. I tried it under my 40 and WOW, what a difference it made! The pad I have is the 1/4" thick type similar to plexiglass, without the little sharp carpet nubs on the back.
Hope this is helpful
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02-09-08, 05:13 AM
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#19 (permalink)
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Focus on the Journey
Join Date: Jun 2005
Location: Southern Arizona
Posts: 1,341
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Quote:
Originally Posted by handcannon
bsevens
You seem to have so many good ideas and info to share with us here on mud so maybe I can return the favor now. I am also having to lay on gravel to work under my 40 for now. Then--- I spied a floor pad that goes under an office chair. I tried it under my 40 and WOW, what a difference it made! The pad I have is the 1/4" thick type similar to plexiglass, without the little sharp carpet nubs on the back.
Hope this is helpful
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Thanks, and that's a great idea. I'm going to Costco today.
__________________
78 FJ40
ARB's F&R, Rear Disks, DUI HEI, 200 Amp Alt, OME 2.5, 33x10.50, PS, RE8000, Stout Rear Bumper, 4+Plus Sliders/U-Bolt Flip Kit/Tie & Relay Rods/Anti-Inversion Shackles, Dual Tanks, BTB Dash Box, Tuned Ceramic Coated Headers, Extended Axle Vents, BrakeQuip Custom Certified SS Brake & Clutch Flex Lines
ROTW My Yoda| HD Skid Plate| Recovery & Windshield Washer Tanks| Toyota Pulley on GM Pump| Bypass Hose| Vapor Recovery Tank
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02-10-08, 11:34 AM
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#20 (permalink)
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Forum Regular
Join Date: Jan 2008
Location: Charleston S.C.
Posts: 233
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Which seal is it that causes this? I'd like to have one on hand when I do my 4spd tranny swap in my 72 with the original transfer case. I might as well replace this seal while it's all torn apart. I think I'll add this bypass also as an extra precaution.
__________________
72 FJ40, 4spd, D.U.I. ignition, Downey Header, Power Steering, Center-Force clutch, 4"springs, Hyper Shackles, Front disc's, 35" BFG Mud Terrains, Detroit Lockers, Yukon 4:88's, Longfield Axles, Custom cage and bumpers, Mile marker 9000, Summit Fuel Cell
Upstate Cruisers-
Lowcountry Chapter
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02-10-08, 05:46 PM
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#21 (permalink)
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Forum Lifer
Join Date: Jun 2004
Location: Northern Colorado
Posts: 5,599
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Quote:
Originally Posted by dgangle
For as much work as it took sourcing all this stuff and as nice and well-thought out virtually every part of your truck is, why the band-aid?
I realize it's a $6 seal and a little more work than most are willing or able, but why not just fix the problem?
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x2, and I do not have a nice heated shop to work in. I would rather spend the energy on the repair vs. bypass.
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02-10-08, 05:48 PM
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#22 (permalink)
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Forum Lifer
Join Date: Jun 2004
Location: Northern Colorado
Posts: 5,599
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Quote:
Originally Posted by rchandler
Which way does the oil tend to go if seal is bad TC or tranny ?
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Quote:
Originally Posted by bsevans
In a Landcruiser it always pumps from the transfer to the tranny. In a Jeep it is normally the other way around. It pumps from the unit that has the higher pressure to the unit with the lower pressure. The hose helps reduce the pressure differential and lets the excess pumped into the tranny drain back to the transfer case.
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I believe when the seal is failing, it pumps to the tranny, and once the seal has fully failed it goes tranny to t-case...
Moral of the story: check fluid in both
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02-12-08, 11:38 PM
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#23 (permalink)
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250+ Club
Join Date: Aug 2006
Location: L.A., Cali
Posts: 289
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I have one of these hoses for my old 4 speed I took out. It sounds like it would be advisable to put it in my 5 speed just in case.
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'73 FJ40 - In progress
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02-13-08, 03:47 AM
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#24 (permalink)
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250+ Club
Join Date: Jul 2004
Posts: 355
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Yeah, would you guys continue to run with it anyways even after fixing the seal?
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02-13-08, 07:17 AM
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#25 (permalink)
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250+ Club
Join Date: Dec 2005
Location: Craig, CO
Posts: 590
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I have a question, I have a leaking seal between the two, actually started leaking within 10,000 miles of replacement. But I have a PTO, toyota stock unit fitted to the transfer. So the hose will not run right. It is mentioned above that part of the issue is pressure. Will a hose between the two help at all? It probably won't allow the fluid to gravity feed back to the transfer, but would it equalize the pressure such that the transfer of fluid would be reduced.
Any insight on this, anyone?
__________________
1996 T100, Stock, nice truck
1973 FJ-40, Stock
1984 FJ-60, Stock, 225,000+miles 
2002 Subaru Forester L, for the wifey
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02-13-08, 10:46 AM
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#26 (permalink)
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250+ Club
Join Date: Jan 2003
Posts: 443
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I'm planning on leaving it on even after I fix the seal because there's no reason to take it off. I see no disadvantages to having the hose connected, it can only help if the seal does fail again.
I was also curious to know whether a pressure difference was the root cause behind the fluid transfer, so I felt around the transfercase vent and I didn't see a problem. So I suspect there must be another reason for the oil moving upward. I started to remove the tranny cover to get a better access at the vent, but ran out of time and had to button it all back up to drive it. Next time I take off the cover, I'm going to disassemble the vent and add a breather hose, so I'll know for sure if the vent is plugged. But my guess right now is that pressure differential is not the primary cause of the problem. Other than that bit of info, I can't really help you.
Last edited by ducktapeguy; 02-13-08 at 10:52 AM.
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02-13-08, 03:18 PM
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#27 (permalink)
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Forum Lifer
Join Date: Jan 2003
Location: Chandler, Az.
Posts: 2,569
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I made my first one of these about 30 years ago for my 72 FJ-40. I went lo-tech. I drilled out the two inspection plugs and tapped a thread in them to fit a brass hose barb. Connect the barbs with 5/16 fuel line. Lasted for years. Never leaked. As long as the breather on the transfer is working, there is no pressure in this line, just gravity feed gear oil trickling from the transmission down to the transfer. Cost was under $10, and I did it with a hand drill, hand tap, and a bench vice. Only drawback to leaving it on permanently is just a minor nusiance value when checking fluid levels. John
__________________
76 FJ55, Safari Grade. 350 SBC, Lockrightx2, SO, SR, PS, York on board, 35" Krawlers, and way too much junk in the trunk!!!! 
85 Toyota mini truck  for chase/support!
CSC #41
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02-14-08, 12:23 AM
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#28 (permalink)
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250+ Club
Join Date: Jul 2004
Posts: 355
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Ta Ink, that is how mine is at the moment.
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02-14-08, 12:34 PM
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#29 (permalink)
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250+ Club
Join Date: Dec 2007
Location: Orcas Island in NW Washington State
Posts: 541
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My seal have been shot because it always ran into the transfer. In that case the bypass hose didnt help at all. So I did the hose barb fittings and plumbed in a pump off of a 90 wt pump bottle, sorta like the ones for hand soap. It had a clear vinyl tube going back up to the tranny. Just every now and then, I would climb under and pump untill no more gear lube was moving through the line....I saw a picture of it on Landpimps gallery, so I'm thinking it must still be functional. Not a setup for serious off-road work, but it looked way easier than pulling everything apart.
__________________
Some old Ford one ton pickups,'66 fj 45 lpb, '79 fj 55, '66 BSA 441 victor special,BMW r75/5 toaster tank, Ancient one lung engines (1912 Stover...6" bore, 12"stroke, 8 hp at max 300 rpms, 2125 lbs) Never without an old 'cruiser for 23 years. Everything runs, and is mostly original, That's how we roll on Mt. Pickett....
'Rusty ol' floorboards, hot on their feet...' Alan Jackson
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01-21-09, 10:16 AM
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#30 (permalink)
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Site Addict
Join Date: Nov 2004
Location: MD
Posts: 1,370
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Bsevens, do you know if there is a fitting that fits directly into the fill holes without adapters? I have the MAF version, and to view/check the level of gear oil, I have to remove the adapter. This would also avoid using two wrenches.
Thanks, Dan
__________________
'77 FJ40: HFS, 33's, Locked and Low'd
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