Leak at Transfer Case Output (5 Viewers)

[Toler]

Hi everyone,

My '73 FJ40 (3 spd) has been dropping a oil from the parking brake housing. I removed the drive shaft, parking brake housing and flange that's connected to the transfer case, and tracked it down to oil coming through where the bearings are(sorry - don't know the name of the part).

Hoping I can lean on the collective experience of this knowledgeable group for guidance on what needed to remedy this situation.

Thanks in advance for any help with this guys.

 

[4Cruisers]

Here's the best long-term solution:

Speedo housing leaks ........ Valley Hybrids dual seal housings.

We’ve had a number of inquiries for these recently so I thought I’d start a thread. As most of you know, the most common transfer case leak on any FJ 40, 45 or 55 is typically the rear extension housing and E break area. Quite a number of years ago somebody came up with the idea to put two...

forum.ih8mud.com

Other than that, if there's a groove that's letting gear oil past the seal, you can get a Speedi-Sleeve to slip over the shaft.

 

[Toler]

Here's the best long-term solution:

Speedo housing leaks ........ Valley Hybrids dual seal housings.

We’ve had a number of inquiries for these recently so I thought I’d start a thread. As most of you know, the most common transfer case leak on any FJ 40, 45 or 55 is typically the rear extension housing and E break area. Quite a number of years ago somebody came up with the idea to put two...

forum.ih8mud.com

Other than that, if there's a groove that's letting gear oil past the seal, you can get a Speedi-Sleeve to slip over the shaft.

Thank you for the reply and link.

Are Speedi-Sleeves a universal part - or is there a specific size (or provider) that I should be looking for?
Also, is it also called a Transfer Case Extension Housing Repair Sleeve?

Thanks again.

 

[4Cruisers]

A quick search here on MUD should answer the question. I'm thinking Summit Racing has them specific for this application, but I'm not sure.

 

[Toler]

A quick search here on MUD should answer the question. I'm thinking Summit Racing has them specific for this application, but I'm not sure.

Looks like Poser has posted the part reference a few times - CR 99177 (Thanks @Poser)

But should the bearings be leaking like that – or does the sleeve go BEHIND the bearings? Sorry for the remedial questions. Learning.

Thanks

 

[bhsdriller]

The sleeve goes on your parking brake drum. Post a picture of it, there's probably a groove worn from the seal.

If there's oil in the transfer case still it will leak, there's nothing holding it in. The seal on the speedometer housing you pulled off keeps it in.


99177 is correct I just did the repair. Carquest and Napa had them here locally.

 

[Toler]

The sleeve goes on your parking brake drum. Post a picture of it, there's probably a groove worn from the seal.

If there's oil in the transfer case still it will leak, there's nothing holding it in. The seal on the speedometer housing you pulled off keeps it in.


99177 is correct I just did the repair. Carquest and Napa had them here locally.

Ah!, got it. Thanks for the clarity - like I said - learning.
I was scratching my head wondering how a circular sleeve around a spline shaft would prevent the leak.

So if I'm following along, it sounds like it goes on this shaft of the drum.

Will clean-up all the parts that I pulled thus far. Picking-up the 99177 part shortly.

Thanks for the guidance - much appreciated.

 

[bhsdriller]

Yes, you drive it down onto the shaft to cover those seal wear points.

 

[Toler]

Yes, you drive it down onto the shaft to cover those seal wear points.

OK. Job completed, took it for a spin a few hours ago. Wne outside just now & noticed that it's still dropping oil from the parking brake housing.
Thoughts???

 

[middlecalf]

Did you put sealant on the splines?

 

[bhsdriller]

Did you replace the rear output seal?

Usually it's all done at once...seal, sleeve and the silicone on the splines like he mentioned ^
Search around there's a ton of good threads on it.

Also this is a common mod done at the same time.

Speedo housing leaks ........ Valley Hybrids dual seal housings.

We’ve had a number of inquiries for these recently so I thought I’d start a thread. As most of you know, the most common transfer case leak on any FJ 40, 45 or 55 is typically the rear extension housing and E break area. Quite a number of years ago somebody came up with the idea to put two...

forum.ih8mud.com

 

[Toler]

Did you put sealant on the splines?

I did not. Thought I had the answers when I started. I appreciate the detail.

Thank you. Cheers.

 

[Toler]

Did you replace the rear output seal?

Usually it's all done at once...seal, sleeve and the silicone on the splines like he mentioned ^
Search around there's a ton of good threads on it.

Also this is a common mod done at the same time.

Speedo housing leaks ........ Valley Hybrids dual seal housings.

We’ve had a number of inquiries for these recently so I thought I’d start a thread. As most of you know, the most common transfer case leak on any FJ 40, 45 or 55 is typically the rear extension housing and E break area. Quite a number of years ago somebody came up with the idea to put two...

forum.ih8mud.com

Did you replace the rear output seal?

Usually it's all done at once...seal, sleeve and the silicone on the splines like he mentioned ^
Search around there's a ton of good threads on it.

Also this is a common mod done at the same time.

Speedo housing leaks ........ Valley Hybrids dual seal housings.

We’ve had a number of inquiries for these recently so I thought I’d start a thread. As most of you know, the most common transfer case leak on any FJ 40, 45 or 55 is typically the rear extension housing and E break area. Quite a number of years ago somebody came up with the idea to put two...

forum.ih8mud.com

The context you guys have shared is greatly appreciated, and this has been a valuable experience for my son and I as we bond while building our wrenching skills.

Since I have to get back under the truck, I'm going to order the Valley Hybrids kit and do this right.
From what I've read, the silicone gets applied behind the washer & nut that holds the drum in place - can someone please confirm or correct?

Thanks guys!

 

[ceylonfj40nut]

X2 on double seal housing and sealant on splines.

Speedo housing leaks ........ Valley Hybrids dual seal housings.

We’ve had a number of inquiries for these recently so I thought I’d start a thread. As most of you know, the most common transfer case leak on any FJ 40, 45 or 55 is typically the rear extension housing and E break area. Quite a number of years ago somebody came up with the idea to put two...

forum.ih8mud.com

 

[Brimful of FJ]

Hi guys, just came across this post as I have the same issue and am trying to blueprint the plan in my head. I'm still a novice so photos would be most helpful, but I can't understand where the silicone is going when mentioned above? I also don't know the purpose of it which would probably help. And what type of silicone?
Also, the part number of the sleeve is noted, but the seal for this is 90311-45001, is that right? And will the sleeve add much benefit if I'm replacing the seal? I still don't really get what the sleeve is for either. Yes I've looked around, unfortunately for me most people have a clue about things and don't over explain too often. Its hard being new.

 

[45Dougal]

I tried to over-explain when I did this earlier in the year. Hopefully you find this useful.

The silicone sealant goes inside the splines of the brake drum where it sits on the splined drive shaft. If you omit the sealant then you'll get a slow drip.

Transfer Seal and Handbrake replacement

I'm sure this job has been done to death already here, but I've struggled to find a few snippets of information while researching the Transfer Seal Change, and so I thought I'd start a new thread to try and help anyone else in the same boat. I have a 1977 HJ45 with 3.6L H engine and H41...

forum.ih8mud.com

 

[Brimful of FJ]

Thanks @45Dougal, that's a great walkthrough. There should a forum section called 'walkthroughs for dummies' for the novices like myself.
A couple of basic questions if you don't mind...
As I prepare, are there any parts you recommend I replace regardless of condition, other than the crush washer and output seal (car was not well maintained previously).
Is the sleeve's purpose to sit flush against the seal so as to keep it seated? How necessary is it? I have had my vehicle a long time without it being registered. I really just want to register it and drive as it is now driving season. I will have to order the sleeve internationally, so it will set me back timewise.
Does the silicone sealant go in here? (see pic)...
Thanks.

 

[45Dougal]

Correct, that's where the sealant goes.

You only need the speedisleeve if the shaft is worn. The purpose is to make the shaft round again and smooth as it was originally. Its a tight fit on the shaft once its hammered on.
As you'll see on mine, there wasn't a huge wear mark on the shaft but it was enough to damage the seal and make it leak, so best to just buy it before you start.

Brake shoes obviously should be replaced, and I painted everything while it was apart too.
A good time to clean your prop shaft and regrease - make sure it goes back on with the same orientation as it came off otherwise it will vibrate badly

 

[Brimful of FJ]

Great stuff @45Dougal, thanks very much.