Fluid from Tranny passing into T Case

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Dec 8, 2016
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arizona
After extensive engine work on my 85 FJ 60. Fuel injection milled head and polished ports knife edge crank, etc.
Installed new T55 five speed and rebuild T case. Later I noticed
A leak started from speedo hole. I found TCase over full, fluid leaking from the tranny into it. I know I put some kind of plug between trans and tcase that came in kit from Georg when I did the job.Did i mess up that little ‘plug’ on install? Also is there any fix short of pulling it apart?
 
You may try check the breather as well..happened on mine few years back after doing the h55 gearbox...hopefully it is just clogged..if not, looks like gonna be big mess.
 
After extensive engine work on my 85 FJ 60. Fuel injection milled head and polished ports knife edge crank, etc.
Installed new T55 five speed and rebuild T case. Later I noticed
A leak started from speedo hole. I found TCase over full, fluid leaking from the tranny into it. I know I put some kind of plug between trans and tcase that came in kit from Georg when I did the job.Did i mess up that little ‘plug’ on install? Also is there any fix short of pulling it apart?

I think the only way to fix this without tearing down the tcase is to run a hose from the tcase back to the tranny. I used that approach successfully until we got around to cracking open the case. Many on here have gone thousands of miles that way. Read more here: Tranny to Transfer case bypass hose
 
The bypass hose mentioned above won't work if the transfer case is over filling.

There's a bolt hole in the front plate of the transfer case that doesn't get used when the 5 speed is attached to it. That hole needs to be plugged. Assuming you plugged it.
It's also possible that the input shaft seal (the main culprit of the leak) didn't seat correctly.
Also if the front O-ring on the idler shaft didn't seat correctly- oil can migrate through there too.

If the leak started after 60K miles I'd just say join the club and level the oils periodically. But since it's brand new — my recommendation is to take it apart and find out what happened.
 
The bypass hose mentioned above won't work if the transfer case is over filling.

There's a bolt hole in the front plate of the transfer case that doesn't get used when the 5 speed is attached to it. That hole needs to be plugged. Assuming you plugged it.
It's also possible that the input shaft seal (the main culprit of the leak) didn't seat correctly.
Also if the front O-ring on the idler shaft didn't seat correctly- oil can migrate through there too.

If the leak started after 60K miles I'd just say join the club and level the oils periodically. But since it's brand new — my recommendation is to take it apart and find out what happened.
I appreciate your help. Curious that fluid on fj60 like mine usually go from t case to tranny.
I put the plug in according to instructions. Must be messed up somewhere but it passes about a cup of fluid Into tranny every few thousand miles. I’ll just watch it for awhile.
Thank you
 
I appreciate your help. Curious that fluid on fj60 like mine usually go from t case to tranny.
I put the plug in according to instructions. Must be messed up somewhere but it passes about a cup of fluid Into tranny every few thousand miles. I’ll just watch it for awhile.
Thank you
Into the transfer case I meant
 

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