TRANS/CLUTCH NOISE?

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Took another drive with the insp cover off. Yikes. it got worse...now it makes the clunking with or without clutch engaged while driving. something's defintely broken in the trans or transfer. I have new oil in it, so I'll start draining and tearing it apart and see what I find. yeah, I knew all the seals were toast. I got everything to rebuild both trans and transfer. plus a new clutch kit, months ago.. Oh well, time to get to work. I'll update here if anyone wants to follow along..
 
Is there any gear lube in the transfer case? With that much gear lube in the bellhousing, it could be a bad front seal or an over full transmission or both. When the seal between the tcase and trans goes bad, the tcase will pump gear lube into the trans. There's a good possibility the clutch disc is contaminated with oil.
 
pb4ugo said:
There's a good possibility the clutch disc is contaminated with oil.
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Im a big fan of wet clutches
10/10....highly recommend.
this was the result of the transfer filling the trans and a questionable front seal.
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I had a wet cluth come apart on a steep uphill with my 3 year old son onboard, started rolling back real fast, I pumped the clutch, it spity all the debris and locked up thank god, there was a small drainage bar that caught us or it would have been nasty. I have a similar issue with my front trans seal, worth removing inspection , on my bellhouse the whole bottom is exposed with cover off and I can push clutch and see if disc is soaked.
 
pb4ugo said:
Is there any gear lube in the transfer case? With that much gear lube in the bellhousing, it could be a bad front seal or an over full transmission or both. When the seal between the tcase and trans goes bad, the tcase will pump gear lube into the trans. There's a good possibility the clutch disc is contaminated with oil.
Click to expand...
You may be on to something, if he doesn't have a bypass hose he could have run the TC dry. I'm sure that would make all kinds on noise coming apart.
 
iirc the the front cone has a drain on the bottom, that imagine is supposed to dump the oil at the throw out bearing...so it doesnt run out the very front and drop on the clutch and pressure plate.
wonder if enlarging that hole would be a thing?
 
The throw out bearing is packed with grease when new and slides on the bearing retainer collar. The bearing retainer has a drain back to allow oil to return back in to the transmission case after lubricating the trans input shaft bearing. There's likely a seal inside the bearing retainer collar.
 
77mustard40 said:
You may be on to something, if he doesn't have a bypass hose he could have run the TC dry. I'm sure that would make all kinds on noise coming apart.
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That'll be the big question..I'm leaning towards the TC being crunched. I changed the fluid a few months back when I almost dropped all of it to work on, but there was still fluid in the TC...I don't believe enough though...maybe just had enough and quit...that 2 hour hwy run last week probably didn't help... I'll make up a line to connect them this time around.
 
pb4ugo said:
The throw out bearing is packed with grease when new and slides on the bearing retainer collar. The bearing retainer has a drain back to allow oil to return back in to the transmission case after lubricating the trans input shaft bearing. There's likely a seal inside the bearing retainer collar.
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yes there is a seal in the retainer, just outboard of the bearing.

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The TC was just shy of a liter of oil. Low, but not bone dry. The oil was very gooey and brown. I literally changed the oil several months ago…wild that it looks so bad already. Trans was better looking, color wise, and had a pretty good amount in it. No obvious metal bits came out. I should able to yank them tomorrow..didn’t have much time today.
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Didn’t seem overfilled, but I haven’t measured the fluid yet. I’ll confirm tomorrow. I don’t have any puddles underneath when I park, so it must be in the trans. I daily drive mine, so it doesn’t get a chance to rest often..I’ll take this opportunity to get her back in shape in the driveline..
 
Ziffdaddy said:
The TC was just shy of a liter of oil. Low, but not bone dry. The oil was very gooey and brown. I literally changed the oil several months ago…wild that it looks so bad already. Trans was better looking, color wise, and had a pretty good amount in it. No obvious metal bits came out. I should able to yank them tomorrow..didn’t have much time today.View attachment 4067005
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FYI - I had a transfer case issue last January making all kinds of weird racket, below was the culprit. High gear was missing a few teeth and turned the gear oil into a chocolate milk looking concoction.

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GA Architect said:
FYI - I had a transfer case issue last January making all kinds of weird racket, below was the culprit. High gear was missing a few teeth and turned the gear oil into a chocolate milk looking concoction.

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Very interesting. That’s pretty crazy. Was it a random fail or were you doing something extreme? The oil in my TC was definitely a chocolate milk looking paste. It’ll be interesting to see what I uncover. Hope it’s not too bad..😬
 
Ziffdaddy said:
Very interesting. That’s pretty crazy. Was it a random fail or were you doing something extreme? The oil in my TC was definitely a chocolate milk looking paste. It’ll be interesting to see what I uncover. Hope it’s not too bad..😬
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Random...I was just on my way home from work, like most any other day, but that day it decided to say something and let me know it wasn't healthy. < Click here > and you can see what the inside of the TC looked like at the time.
 
GA Architect said:
Random...I was just on my way home from work, like most any other day, but that day it decided to say something and let me know it wasn't healthy. < Click here > and you can see what the inside of the TC looked like at the time.
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Holy moly...that's what I'm afraid I'll find.. You had to replace the whole guts of the TC? Was everything just toasted? I'll read through your whole thread before I rebuild...I just need to get the units out first. So much fun..
 
Ok, so the TC came apart very easily. Thankful for that. The only obvious issue was the idler gear, I believe?, has a few teeth knocked off. Some bits in the case and plenty of pulverized metal sludge..
So big question, would those missing teeth make the case clunk clunk like that? Spinning it by hand, it did have resistance where the broken teeth meshed..
Anyone have a good replacement gear? 6/76 fj..

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Sweeeeet!
Anybody have a line on a good used one? Anyone in N Georgia? 😬
 
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