The infamous T150 swapping fluid with D20 issue - JeepForum.com
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post #1 of 4 Old 08-24-2019, 09:55 PM Thread Starter
77jeepcj5
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The infamous T150 swapping fluid with D20 issue

I know this has been beaten to death on here, but I never seem to find a solution on any thread, so here it goes. I rebuilt my T150 and D20. When I pulled the trans there was hardly any fluid in it, and way too much fluid in the transfer case. There also was no rear output seal on the trans. I installed the seal the right direction, fully seated it, and reattached the Tcase. The trans still dumped all the fluid into the T case. I removed the case yet again to find the seal had somehow worked it's way out a few millimeters. I pulled it, replaced it with a new output seal (fully seated), and still, it leaks into the T case. I've tried everything and am at a loss. In my defeat I started to wonder if I could potentially remove the rear output seal and just run a line from the fill plug of the trans to the fill plug on the Tcase so it would always even itself out. Thoughts?? Any help is appreciated. Thanks!

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post #2 of 4 Old 09-01-2019, 10:23 PM Thread Starter
77jeepcj5
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Bump. Crickets
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post #3 of 4 Old 09-02-2019, 10:39 AM
RedNeckCorvette
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For seals in general, If the shaft is worn use a jiffy sleeve, if the seat for the seal is worn ruff it up a bit with a pick or something to create ridges.
Good luck RN
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post #4 of 4 Old 09-07-2019, 07:54 PM Thread Starter
77jeepcj5
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Thanks for the reply RN! I'll look up a jiffy sleeve
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