Edited 11/19/22. This thread gets more into foaming of lubricates, causes and effects. The two main causes of excessive foaming, we're concerned with: Overfilling and contamination. I also came to conclusion, with helpful post from others and looking at adapter case. It would be nearly impossible in the 98-02 to get cross contamination between transmission & transfer case. As such I also change title replacing the words: "ATF" with "overfill!"
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I would think, if gear lube contaminated with ATF, it would foam. What say you mud?
Also, if ATF leaked from transmission into transfer-case. Couldn't it get in gear lube, in the 98-02? I've never pulled one apart, so don't know!
I've got and issue, in a 2001 w/353K miles. It's very clean stock Land Cruiser. With transfer-case leaking rather badly at both forward & aft output shafts. Why is the question! I've seen many, some with more miles, some never flushed, not leak. Never have I seen one leak this bad!
Possibilities:
1) Is bad bearing(s) or gears, causing vibration/wobble, damaging seal(s)? At both end, at same time. Than I'd think it to be a bad transfer case altogether. Seems fine IMO, just in town City & HWY driving.
2) Excessive fluid pressure, which over-filling could cause. Last fill was DIY, and IMO likely under-filled a tad. It was noted leaking, before last flush also.
3) Gone to long before first flush, and old gear lube damaged seal(s). Note: most rubber on vehicle about as one would think or better for age and miles.
4) Contamination in transfer-case gear lube causing excessive foaming of gear lube. Which would greatly increase pressure, and possible blow foam out breather. May explain fluid in breather tube.
5)?
Here is some current history and what I observed:
Owner, DIY changed transmission ATF and transfer-case gear lube. Just before 1,600 miles HWY drive, to me here in Denver. Owner foggy on transmission topping procedure, he used. But seem to be detail oriented and meticulous. He slow filled transfer-case and let run out fill hole, before plugging fill hole. Not letting settle for 15 minutes, than re-topping as FSM recommends. Which generally leaves, just a tad low.
I saw leaks upon inspection. Worst is transfer-case at both out-put shafts. leaving oil spots everywhere it was parked. Also some ATF residue attracting dust on plastic, at bottom of radiator near pre ATF oil cooler nipples/lines, in and out. Found the After-Market (AM) radiator pre cooler nipple's large nuts, needed snugging. Which they often do "right out of the box" in these AM radiator's. ATF cooler hose clamps, not put back in factory indentations (orientation), which can lead to weeps. It did not appear as if a lot of ATF fluid seeped out (see pictures).
Inspection notes:
A) Transfer-case, leaking badly at both ends.
B) Transmission .5 qt low, at between ~158F (ATF Temp, monitored through tech stream).
C) Transfer-case ~1/3 cup over-filled, and leaking badly. Likely under-filled a tad, last flush.
D) ~2 table spoons of what appears to be gear lube, came out of transfer case breathe tube.
Side note: 2 times only, out of about a dozen cold start-ups. I hear a rattle while warming up. Like CAT heat shield loose rattle. Seems to be from mid undercarriage area. Engine cover and both factory under-shielding were off. Found Heat shields and their bolts, to be in excellent condition and tight, no rattle fist pounding test). This rattle was both while idling in N, and while driving in D, until operation temp reached.
Forward output shaft
Aft transfer-case output shaft leak
__________________________________________________________________________
I would think, if gear lube contaminated with ATF, it would foam. What say you mud?
Also, if ATF leaked from transmission into transfer-case. Couldn't it get in gear lube, in the 98-02? I've never pulled one apart, so don't know!
I've got and issue, in a 2001 w/353K miles. It's very clean stock Land Cruiser. With transfer-case leaking rather badly at both forward & aft output shafts. Why is the question! I've seen many, some with more miles, some never flushed, not leak. Never have I seen one leak this bad!
Possibilities:
1) Is bad bearing(s) or gears, causing vibration/wobble, damaging seal(s)? At both end, at same time. Than I'd think it to be a bad transfer case altogether. Seems fine IMO, just in town City & HWY driving.
2) Excessive fluid pressure, which over-filling could cause. Last fill was DIY, and IMO likely under-filled a tad. It was noted leaking, before last flush also.
3) Gone to long before first flush, and old gear lube damaged seal(s). Note: most rubber on vehicle about as one would think or better for age and miles.
4) Contamination in transfer-case gear lube causing excessive foaming of gear lube. Which would greatly increase pressure, and possible blow foam out breather. May explain fluid in breather tube.
5)?
Here is some current history and what I observed:
Owner, DIY changed transmission ATF and transfer-case gear lube. Just before 1,600 miles HWY drive, to me here in Denver. Owner foggy on transmission topping procedure, he used. But seem to be detail oriented and meticulous. He slow filled transfer-case and let run out fill hole, before plugging fill hole. Not letting settle for 15 minutes, than re-topping as FSM recommends. Which generally leaves, just a tad low.
I saw leaks upon inspection. Worst is transfer-case at both out-put shafts. leaving oil spots everywhere it was parked. Also some ATF residue attracting dust on plastic, at bottom of radiator near pre ATF oil cooler nipples/lines, in and out. Found the After-Market (AM) radiator pre cooler nipple's large nuts, needed snugging. Which they often do "right out of the box" in these AM radiator's. ATF cooler hose clamps, not put back in factory indentations (orientation), which can lead to weeps. It did not appear as if a lot of ATF fluid seeped out (see pictures).
Inspection notes:
A) Transfer-case, leaking badly at both ends.
B) Transmission .5 qt low, at between ~158F (ATF Temp, monitored through tech stream).
C) Transfer-case ~1/3 cup over-filled, and leaking badly. Likely under-filled a tad, last flush.
D) ~2 table spoons of what appears to be gear lube, came out of transfer case breathe tube.
Side note: 2 times only, out of about a dozen cold start-ups. I hear a rattle while warming up. Like CAT heat shield loose rattle. Seems to be from mid undercarriage area. Engine cover and both factory under-shielding were off. Found Heat shields and their bolts, to be in excellent condition and tight, no rattle fist pounding test). This rattle was both while idling in N, and while driving in D, until operation temp reached.
Forward output shaft
Aft transfer-case output shaft leak
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