Help with fixing a leak - D20/Cold Duck

[JWMcCrary]

Both cases were leaking pretty bad. Just had them out and resealed and all of that seems fine. This little leak is nothing compared to how it was so I can live with it if I have to. The remaining leak is coming from the unused shift rail hole on the back side of the cold duck. Looks like it was welded when it was built. It was leaking so bad when I pulled it out that I didn't notice it. Is there something that could be put on it that might stop the leak? Seems to only leak after it's been driven at HWY speeds and the gear oil is hot.

 

[broncodriver99]

Is it welded or an aluminum expansion plug? If it is an expansion plug you can pop it out and install a new one with a little sealer around the edge.

 

[JWMcCrary]

I thought it was welded, looking at the pic now though I'm wondering. Will clean it up good when I get it back home. I was so bummed to see gear oil on the parking lot when I went out there.

 

[NYLES]

I think that's a plug that somebody??? beat on trying to get the T case back in.....

 

[JWMcCrary]

Haha, no beating at all, slid right in.

 

[Oildog]

I've had pretty good luck using metal epoxies (JB Weld, for instance) for taking care of issues like that. Key is getting the surface extremely clean and oil free and scuffing the repaired surface. POR 15 makes a putty that is awesome stuff in this application...FWIW...

 

[JWMcCrary]

Got it home and checked it out and it appears it's leaking from a brass screw in plug on the side cover plate. Looks like i may be lucky and it's a easy fix

 

[gddyap]

Mine leaks at the shift rail. I don't think those seals were designed to be under oil all the time.
I've been thinking about replacing my duck. My wife is scared to drive the Bronco because of the 4 floor shifters. And the duck reduction case pops out of low at the most inopportune moments like climbing a ledge.

 

[JWMcCrary]

Knock on wood, I've never had any trouble with it popping out of gear. There is a shift rail seal that is thicker, when seated it isn't flush with the case, those seem to be better.

 

[Viperwolf1]

Mine leaks at the shift rail. I don't think those seals were designed to be under oil all the time.
I've been thinking about replacing my duck. My wife is scared to drive the Bronco because of the 4 floor shifters. And the duck reduction case pops out of low at the most inopportune moments like climbing a ledge.

This might be a good investment: http://shop.broncograveyard.com/Adjustable-Detent-Balls-and-Springs/productinfo/11674A/

 

[DaveLev]

I've had good luck with permatex grey on t-case leaks. Cheaper than a re-seal, and less time consuming.

 

[welndmn]

Ducks just leak, I've never seen a dry one.

Do try and fix it, but if you can't stop all of the leak, don't feel defeated.

 

[JWMcCrary]

Been running the duck for a few years and understand the shift rail leak, have actually had good luck with that. What I thought was a leak is coming from the little plug in the side plate that was welded on when the case was cut. AND, I think I just now realized what that plug is for. Appears you remove and when oil comes out that hole you have it full, or full enough. It's too small to make sense to me for anything else. That being the case I have been running mine way too full.

I tightened that plug and it has quit leaking. (for now)