T-Case, Issue/Rebuild

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Joined
Sep 13, 2006
Threads
124
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Location
Santa Monica, CA
Website
www.elirubelphotography.com
Redoing this intro- after spending half an hour under the rig- posting with more info this time.

Looks like my main issue is the T-Case, which has about an inch of slack. I think I made a really, really stupid mistake- after three years of the cruiser sitting around post CM07 (trailered it home because of a seperate issue, then trailered it to school in California with me, and only now have finished it up and begun to drive it daily) I think I forgot to refill the tcase fluid that spilled out on my chest at 3am all those years ago in Moab that earned my my mud name "90 Weight."

Unfortunately, after all of that time (should have done it immediately after) I may have forgotten to refill the Tcase fluid. Not certain, but I stuck my finger in the fill hole and as far down as I can reach it is completely dry. I will drain the whole thing tomorrow and see how much comes out- but I am afraid this will be the case.

This means I have probably driven 500 miles or less on a near empty (will update the amount that spills out tomorrow) tcase. The sound from the tcase (thought it was the rear diff) has gone from normal, to noisy to very very loud in the last few months as I really started to use it as my daily.

I know, I'm a complete dumbass. Lets get that out of the way. Now its time to figure out what my next move will be.

How difficult is it to rebuild a Tcase? Its one of the few things I didn't deal with during my buildup. So that said I am pretty comfortable with my rig as I did take it down to the frame. Also what should I expect to pay to get the parts to rebuild it?

If I find tomorrow that not much fluid comes out, should I just buy a used Tcase and rebuild it, or take my chances with someones "good" tcase in say the mud classifieds? Or what should I expect to pay for a shop to do it? I really would like to do it myself so I know how to do it in the future, and so I know that it is tight and good to go via me.

Sorry for the back story, hopefully it provides you with a laugh at my expense and if you were at CM07 I'm sure your still keeled over laughing.

Thanks.
 
I just went through this and it was extremely easy. I bought a case from Poser because mine was cracked. I bought gears from NorthCountryLandcruisers. And I bought the rebuild kit from Kurt at Cruiser Outfitters. All three were excellent to deal with quality parts with fast shipping.
 
Find a good used tcase and rebuild it. It's not hard to do. A quality rebuild kit (seals, bearing, idler shaft, etc.) is $200 - $250. PM sent.
 
You figured anything out on this yet bud?
 
You figured anything out on this yet bud?

pictures pictures pictures- didn't get off work till after dark so hopefully the flash is enough to show you whats going on in there. I had no idea what I was looking for so just took a few pictures of the inside, the adapter etc. With the cover off, I could reach my hand in about an inch below the bottom of the cover and feel oil...

What do you think? The edges were definitely not sharp...so thats a good thing right?

Picture 7.jpg

Picture 6.jpg

Picture 8.jpg
Picture 7.jpg
Picture 6.jpg
Picture 8.jpg
 
Well,


It sure looks like you have automatic transmission fluid in your transfer case; that is not a good thing, but with that said however, any oil is better than no oil. :) You may find that the case is not as tore up as you think. Did you drain the oil yet? How pretty was that?


That is a four-speed 16-spline transfer case. That input gear is not the prettiest I have seen, but it does not look like it would cause you to walk either.

Any more pictures of that transfer case adapter?
 
Well,


It sure looks like you have automatic transmission fluid in your transfer case; that is not a good thing, but with that said however, any oil is better than no oil. :) You may find that the case is not as tore up as you think. Did you drain the oil yet? How pretty was that?


That is a four-speed 16-spline transfer case. That input gear is not the prettiest I have seen, but it does not look like it would cause you to walk either.

Any more pictures of that transfer case adapter?

Hmm.

I can take some more photo's tomorrow, though its tough to find a better angle- what are you looking for in the picture?

Havent drained the fluid b/c I don't have a garage to work on it in so it has to be able to drive around. I suppose I could drain the oil tmrow and then fill it back up right away....

George said he had some cases- you think this might not need that serious of an overhaul, or is it still to early to tell?
 
Hmm.

I can take some more photo's tomorrow, though its tough to find a better angle- what are you looking for in the picture?

Havent drained the fluid b/c I don't have a garage to work on it in so it has to be able to drive around. I suppose I could drain the oil tmrow and then fill it back up right away....

George said he had some cases- you think this might not need that serious of an overhaul, or is it still to early to tell?




Lets see what comes out of the transfer case....
 
If you don't have ridges on the top of the gear tooth that is a good sign. If you want to check your backlash / gear mesh let me know and I'll share how I do it. (Strips of notebook paper between the teeth checking for even oil permeation and laceration marks.). Not that you need to go that far.

Mobile makes a good synthetic gear lube that I use in my diffs and trans and would recommend.

Gear Lubricants

They also do oil analysis if you send them samples they can classify foreign material to help you identify premature part failure.

Dave
 

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