Transfer Case Leaking

bataleon · 08-27-2012, 12:16 PM

So i was driving down the highway and smoke started coming from under the heep. I had just finished swapping in a new transfer case (242) and it looks like the rear output might be leaking. I replaced all of the seals and bearings and even put a new oil slinger on it while i was doing the swap, so all parts should be ok.

This struck me as odd: I noticed the smoking and immediately found the nearest parking lot. I got under and found fluid flung all around the jeeps belly and exhaust(hence the smoke) right over the rear of the tcase. i cleaned the fluid up with a rag and limped the couple miles home. when i got home there was no new fluid anywhere, and i hadn't noticed any more smoke while driving.

Thanks for your thoughts guys

**DoctorTim** · 08-27-2012, 12:20 PM

my guess is you didn't install a seal or gasket the correct way. if it stopped leaking for no apparent reason, that could mean theres no more oil to leak out. take out the tcase and check the seals and gaskets. also, get an SYE while you're at it.

bataleon · 08-27-2012, 12:42 PM

Quote:

Originally Posted by XJ-Tim

my guess is you didn't install a seal or gasket the correct way. if it stopped leaking for no apparent reason, that could mean theres no more oil to leak out. take out the tcase and check the seals and gaskets. also, get an SYE while you're at it.

Haha paypal me the money to get one

I do agree that i probably lost enough fluid until no more could be ejected.

I will check to see if the seal was installed properly on the rear. That would mean im dumber than i thought, however it would be the simplest fix so i hope thats it. Time to get back outside....

88cheapcherokee · 08-27-2012, 12:47 PM

"I do agree that i probably lost enough fluid until no more could be ejected."

Hahahahahahahahah that's what she said.

Paradise XJ · 08-27-2012, 12:49 PM

Is the vent and tubing on top all connected and intact?

**rapidcycler** · 08-27-2012, 01:08 PM

When this happened to me, it was the o-ring on the speedo... As good a place as any to start.

bataleon · 08-27-2012, 01:16 PM

Quote:

Originally Posted by 88cheapcherokee

Hahahahahahahahah that's what she said.

Awww man I walked right in to that one!

Quote:

Originally Posted by Paradise XJ

Is the vent and tubing on top all connected and intact?

Yes sir. I actually have it on there with a hose clamp all torqued down and such. Any way it could be on too tight?

Quote:

Originally Posted by rapidcycler

When this happened to me, it was the o-ring on the speedo... As good a place as any to start.

Absolutely. Thats right in the ballpark. I hope its just an o-ring. That'd be soooo nice...

**I forgot to mention that it is still practically full of fluid. I would say full, but i know I lost some lol

bataleon · 08-28-2012, 09:26 AM

Does anyone know of a part number for the o-ring? My searches aren't turning anything up

**rapidcycler** · 08-28-2012, 11:43 AM

Quote:

Originally Posted by bataleon

Does anyone know of a part number for the o-ring? My searches aren't turning anything up

Bah, go to any auto parts store and get an o-ring of similar thickness that fits around the speedo. Take the old one, or the pieces of it, for reference. Or take the whole speedo sensor off. Mind you, I have an NP231, and it was an easy disconnect. I got one from home depot from a water faucet repair kit. ADvanced auto, track auto, pep boys. nothing special about it that I know of, except it keeps your TCase fluid IN your tcase...lol. Advanced Auto has an o-ring "pack", it has one inside of it that will work.

Did you confirm it was the o-ring? or you just gonna replace and see? Mine was visibly broken when I went back to redo the RTV on the small case housing (I thought that was the source of the leak). When I pulled the speedo sensor out, I could see that a piece of the o-ring was still in the threads. It was hard to find the source of the leak, as you know, because it splatters everywhere. I had atf splattering my muffler, running down my driveshaft, sprayed everywhere. Drove it up and down my street after hosing it off, no leak. Took it for 2 minutes on highway, atf was everywhere again.

bataleon · 08-28-2012, 12:45 PM

Quote:

Originally Posted by rapidcycler

Did you confirm it was the o-ring? or you just gonna replace and see? Mine was visibly broken when I went back to redo the RTV on the small case housing (I thought that was the source of the leak). When I pulled the speedo sensor out, I could see that a piece of the o-ring was still in the threads. It was hard to find the source of the leak, as you know, because it splatters everywhere. I had atf splattering my muffler, running down my driveshaft, sprayed everywhere. Drove it up and down my street after hosing it off, no leak. Took it for 2 minutes on highway, atf was everywhere again.

Ya i went with the guess/check method haha and replaced the o-ring today. It was not the source of the leak, however it was a great place to start. Im gonna check my breather tube and output seal once it stops raining.

**rapidcycler** · 08-28-2012, 03:39 PM

Quote:

Originally Posted by bataleon

Ya i went with the guess/check method haha and replaced the o-ring today. It was not the source of the leak, however it was a great place to start. Im gonna check my breather tube and output seal once it stops raining.

yeah, output seal would make sense too. It spinning off the driveshaft everywhere. I feel for ya, it's very nerve wracking to think you're gonna run dry on tcase fluid. Post back when you find it and let me know what it was.