ATF leak between transfer case and trans help needed

[inv3ctiv3]

Long story short the 62 I bought from my friend has a massive trans fluid leak. He said it’s been leaking forever and just tops off the atf but that’s unacceptable for me so I started digging. I found a huge glob of silicon on the TC up above the crossmember. My plan is to drain the trans and TC, remove the crossmember and really see what’s going on.

My question is this, obviously the TC isn’t supposed to have ATF and there’s that cast spacer between the TC/trans so what should I expect to replace? Output shaft seal? Anything else? Should I expect tonnage to drop in split the TC?

After degreasing everything today I could see the drip forming at the seam from the spacer to the TC

This is looking at the TC from the trans side with the back of the truck in the background

 

[3_puppies]

ATF in trans
80/90 gear oil in transfer
oils are separate and don't mingle

until more diagnosis, it is hard to give an answer.

 

[inv3ctiv3]

ATF in trans
80/90 gear oil in transfer
oils are separate and don't mingle

until more diagnosis, it is hard to give an answer.

Yeah, I understand that I’m just trying to figure out what is the best plan I have attack here. I would prefer to not have to drop the transmission so I’m trying to gauge what my best option is to diagnose this.

 

[Eurasiaoverland]

The transfer needs to come off at a minimum, you can remove it in situ (no need to drop the whole transmission). You'll need some sort of puller to remove the transfer input gear.

 

[tmxmotorsports]

Drain the transmission before you pull the split case apart or your gonna have a huge mess believe me from experience.

 

[inv3ctiv3]

The transfer needs to come off at a minimum, you can remove it in situ (no need to drop the whole transmission). You'll need some sort of puller to remove the transfer input gear.

Awesome yea I guess I'll get after that in the next couple of days.

Drain the transmission before you pull the split case apart or your gonna have a huge mess believe me from experience.

Definitely planned on doing that haha!

 

[diesellibrarian]

On a split case, you don't "remove" the transfer case so much as "dismantle it in situ." In other words, it has to be taken apart piece by piece while still attached to the transmission. I haven't done this job myself (yet), but I'm given to understand that it's not too difficult. Just make sure you have a copy of the Factory Service Manual and a knowledgeable parts supplier such as Cruiser Outfitters, Valley Hybrids, etc.

 

[inv3ctiv3]

On a split case, you don't "remove" the transfer case so much as "dismantle it in situ." In other words, it has to be taken apart piece by piece while still attached to the transmission. I haven't done this job myself (yet), but I'm given to understand that it's not too difficult. Just make sure you have a copy of the Factory Service Manual and a knowledgeable parts supplier such as Cruiser Outfitters, Valley Hybrids, etc.

Yup I've helped do it on my friend's HJ61 but it was for a different issue.

 

[inv3ctiv3]

Got the silicon glob out and found the problem. The paper gasket between the cast spacer and TC is torn and missing. Gonna order a TC rebuild kit from cruiser teq and get this thing apart.

 

[3_puppies]

hard to see in the pic but it looks like some aluminum is missing from the housing

 

[BrickRunner]

Got the silicon glob out and found the problem. The paper gasket between the cast spacer and TC is torn and missing. Gonna order a TC rebuild kit from cruiser teq and get this thing apart.

View attachment 4072043

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If you are still thinking about bigger tires, you might consider the 10% under drive high range transfer case gears instead of regearing the differentials since you are opening up the transfer case anyway. And also get 3:1 or 4:1 low range gears while you are at it...

Let me know if you need to borrow some pullers and/or jacks.

 

[inv3ctiv3]

hard to see in the pic but it looks like some aluminum is missing from the housing

Yea I think it's just a weird reflection from the light but I'll find out in a few days I suppose....

If you are still thinking about bigger tires, you might consider the 10% under drive high range transfer case gears instead of regearing the differentials since you are opening up the transfer case anyway. And also get 3:1 or 4:1 low range gears while you are at it...

Let me know if you need to borrow some pullers and/or jacks.

Thanks dude I might definitely need some help haha. I'll have to research those gears, you said I'd have to modify the case right?

 

[BrickRunner]

Yea I think it's just a weird reflection from the light but I'll find out in a few days I suppose....



Thanks dude I might definitely need some help haha. I'll have to research those gears, you said I'd have to modify the case right?

Yeah, since the lower low gear is physically larger, you have to clearance the rear case half.

 

[inv3ctiv3]

Transfer case rebuild kit came in from cruiser teq and I drained the trans/TC. It’s still leaking like crazy so I guess that spacer is full of trans fluid but when I drained the TC it was gear oil it didn’t look like any red atf was mixed in. So that would mean the output shaft seal of the trans is bad?

 

[3_puppies]

ATF from the auto will be all the way to the front half of the transfer case
there is a paper gasket between the front of the transfer and the back of the trans

if it is leaking ATF something at the place where the trans and transfer meet up is not sealing, either the gasket or the trans output seal, or the oring on the idler shaft
or the transfer case has housing has an issue

 

[inv3ctiv3]

ATF from the auto will be all the way to the front half of the transfer case
there is a paper gasket between the front of the transfer and the back of the trans

if it is leaking ATF something at the place where the trans and transfer meet up is not sealing, either the gasket or the trans output seal, or the oring on the idler shaft
or the transfer case has housing has an issue

Ok that first part is what I wanted to know. I couldn't remember if ATF runs all the way through the spacer to the front face of the TC so that makes sense. I am trying to reduce the amount of time this thing is down in my driveway so just trying to be proactive and make sure I have all the parts ordered that I can. Obviously I won't know more till it's apart though.

 

[3_puppies]

Ok that first part is what I wanted to know. I couldn't remember if ATF runs all the way through the spacer to the front face of the TC so that makes sense. I am trying to reduce the amount of time this thing is down in my driveway so just trying to be proactive and make sure I have all the parts ordered that I can. Obviously I won't know more till it's apart though.

as stated above by another member, if you don't drain the trans, when you remove the idler shaft, you will get a bath in ATF

 

[inv3ctiv3]

as stated above by another member, if you don't drain the trans, when you remove the idler shaft, you will get a bath in ATF

Yea like I posted above I drained the trans and TC which is why I was surprised it was still leaking as much as it was.

 

[inv3ctiv3]

Got it all apart and sure enough the gasket had torn and was missing a few pieces hence the silicon. Luckily the case doesn’t appear damaged anywhere. Going to go over everything on Sunday and hopefully get it back together.

 

[Eurasiaoverland]

Interesting to see, I don't think i've ever seen a photo of the back end of an auto in a 60.

Be sure to replace the input shaft seal in the front half of the transfer case and the thick o-ring behind the output shaft bearing.