Atf leaking from Toyota split transfer case in fj60 with vortec and auto swap
- Thread starter Shebamacalla
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Hi @Shebamacalla , you can remove and inspect the retainer bolt, but do not pull out the shaft, there are crush washers at the beginning and the end of that shaft, and if you remove it, unless you open the whole TC, you won't be able to put it back in the right position if they move.
That shaft has an o-ring which seal that shaft, so if oil is coming from there, you will have to replace it. However, due that ATF is lighter than gear oil, that's probably why is leaking, and maybe, just maybe, with just gear oil, you could be ok.
Mauricio.
- Thread starter
- #23
So I drained the case. Lots of red fluid came out when I removed the fill plug and then the rest came out when I removed the drain plug.
The drain plug had what I would assume is a large amount of metal shavings on it.
- Thread starter
- #26
The fluid I caught in the drain pan seems to be straight atf. It is about the same color pinkish red as the atf on the transmission dipstick. So I'm assuming it was just filled with atf instead of gear oil. But I can't figure out how it was filled above the fill port unless it is also leaking in from the auto tranny. But the tranny is not low on fluid according to the dipstick. Is there another bolt that could be used to fill the transfer case that someone might have used by mistake?
Best bet is to fill the TC with the right amount and gear oil and run it.. As stated earlier for a few 100 miles.. Then check and replace if dirty with ATF
This will rule out if ATF is making into your TC, or not, and or if it was filled with ATF to begin with.
Whether you, or a shop diving into a TC rebuild in the middle of a trip..is not advisable our at least a last resort...provided the shop knows what they doing..
This will rule out if ATF is making into your TC, or not, and or if it was filled with ATF to begin with.
Whether you, or a shop diving into a TC rebuild in the middle of a trip..is not advisable our at least a last resort...provided the shop knows what they doing..
Hi @Shebamacalla , if it was full of only ATF, I agree with @MANUCHAO and @theron just put fresh gear oil (we use all the 85W-140 which is heavier gear oil and works perfect in the TC), so fill it up with new gear oil, drive it for a while, I will also say about 500 miles and check again. If you still have more ATF in the TC, then you have a seal issue in your tranny, if not ATF, well, who ever put oil in the transfer, they put the wrong oil in it.
Also, you have might have a little extra metal shaving in the plug due to the wrong oil in the transfer case, so it was not operating properly. In my opinion, not a big deal, and even better if you put the heavier gear oil, unless you hear an uncommon noise while driving.
Hope this helps.
Mauricio.
I'm getting ATF in my transfer as well. It started pretty soon after my swap.
I have not yet torn it down to see where it is making its way through.
I have not yet torn it down to see where it is making its way through.
- Thread starter
- #32
That's was my plan as well @theron @MANUCHAO @dbleon @amazonia4x4 I fully drained it and filled it with 80w90 gear oil. Im most likely heading about 550 miles to North Carolina next so I'll do it again when I get there to see if it's been contaminated with atf or if there are a lot more metal shavings.
Thanks so much for everyone's help. This site continues to make my cruiser life much easier and enjoyable! [emoji482]
Thanks so much for everyone's help. This site continues to make my cruiser life much easier and enjoyable! [emoji482]
Are you checking the ATF in your transmission with the fluid hot, engine idling in park? That extra ATF could have transferred to the transfer case before you purchased the cruiser and the previous owner kept filling up the transmission. With that much fluid I would hazard a guess that your transmission output seal and transfer case input seal are toast.
I don't remember there being any sort of seal on the transmission that would keep ATF from flowing into the adapter.
There is a sealed bearing and the input seal on the transfer case.
Does the tail housing on a 4L60E normally fill up with fluid to the level of the output shaft? That is how full the adapter has to becone to allow ATF through (unless I'm missing some other route).
That I don't know. I don't have an auto behind my motor swap. Stranger things have happened I suppose. Will be interesting to see what the issue is.
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There should be a little bit of metal shavings on the drain plug, that's a natural and normal feature of
helical-cut gears meshing.
This whole thing is simple, and it's one of two things.
1. The seal is shot (most likely)
2. Someone filled your transfer case with ATF
You drained it and some gear oil came out right? If so, the rule out #2.
helical-cut gears meshing.
This whole thing is simple, and it's one of two things.
1. The seal is shot (most likely)
2. Someone filled your transfer case with ATF
You drained it and some gear oil came out right? If so, the rule out #2.
- Thread starter
- #37
So I have about 500 miles on the new oil and on the last hour of my trip the transmission started acting a bit funny. I stopped at a toll booth and when I went to drive away it acted like it was in neutral even though I left it in drive with just my foot on the brake. It then went into drive and got me home. It still has a leak on the back of the case coming from the idler shaft area. I checked the transmission Fluid level and it appears to be lower than it was before. I need to empty the transfer case oil again to inspect further but I believe it will be contaminated with atf. Assuming that is the case how hard is it to replace the seal and could oil have made its way from the transfer case into the transmission?
Mauricio, did you check your records to see if the case was indeed rebuilt there? I found the paper work from the PO where he said it was right before I purchased and I haven't had anyone work on it since I have owned it for 1.5 years.
Sent from my iPhone
Mauricio, did you check your records to see if the case was indeed rebuilt there? I found the paper work from the PO where he said it was right before I purchased and I haven't had anyone work on it since I have owned it for 1.5 years.
Sent from my iPhone
@Shebamacalla
The transmission feeling like it's in neutral probably means you're low on fluid. You can't always trust the dipstick. there are a few different pans
and dip stick combos out there and aftermarket sticks that aren't always up to factory standards.
Or...If you haven't changed your trans filter lately you might do that. As the clutch packs wear the friction material begins to clog the filter.
You can lose pressure in the system and the clutches don't grab. Many times when this happens, you'll drive a while and the system starts to gradually slip more and more. When you stop some of the gunk in the pan will drop from the filter to the bottom and allow flow again. It will take off
normal and then repeat the cycle as the fluid stirs up the gunk in the pan.
If you've been driving on a cronically low fluid level you may be wearing the clutch packs a little faster
The transmission feeling like it's in neutral probably means you're low on fluid. You can't always trust the dipstick. there are a few different pans
and dip stick combos out there and aftermarket sticks that aren't always up to factory standards.
Or...If you haven't changed your trans filter lately you might do that. As the clutch packs wear the friction material begins to clog the filter.
You can lose pressure in the system and the clutches don't grab. Many times when this happens, you'll drive a while and the system starts to gradually slip more and more. When you stop some of the gunk in the pan will drop from the filter to the bottom and allow flow again. It will take off
normal and then repeat the cycle as the fluid stirs up the gunk in the pan.
If you've been driving on a cronically low fluid level you may be wearing the clutch packs a little faster
- Thread starter
- #39
Thanks @lcwizard I have been keeping an eye on the fluid level in the transmission and it has always been a little over filled on the dip stick. but I went to check it yesterday and it was lower than I had previously seen it but still at the cold line (it was cold at the time) I was going to warm it up and try again and change the transfer case oil as well again but then my fusible link blew (asked about that in another thread) so now the truck is just sitting until I can get a new fusible link. My main worry was that oil from the transfer case made it into the transmission. I have read on here about people purposefully putting aft in the transfer case if they know there is a leaking seal between the two so as to not cross contaminate, and saying having ATF in your transfer case is much better than getting oil in the transmission. I am also noticing more leaks now coming from around the adapter between the transmission and transfer. This is making me want to tear the whole thing out and start over. might as well even put in a manual transmission because I really miss having one. who knows 
I've run a half dozen of those adapters and never had the sealed bearing fail like that . The adapter is dropped with the t-case so replacing that bearing a pretty simple bench operation. there are four bolts that hold the adapter to the tranny
