Leaking Transfer Case

[GSP9]

Transfer Case has leaked since the day I bought it. Initially, it was leaking from the fill plug and two of the lower bolts that hold the lower cover plate on. Took the fill plug out along with all the cover plate bolts, sealed the threads, put a new gasket on and they're not leaking anymore. Problem is, I have a new leak. It's small but leaks none the less. I don't think it was leaking from there before. Kind of thinking since the other leaks are now fixed, it's pushing fluid out of this spot. I circled in red where it is leaking from now. Does the bolt above the red circle go into the transfer case? When I had the bottom cover off I don't recall that it did but can't remember. What else is up there that it could be? Thanks.

 

[Viperwolf1]

That's just a rubber bumper on the cross member. Your leak is probably from the adapter to tcase junction.

 

[jmangi62]

I had my D20 comepletely rebuilt and the darn thing leaks like that,just a little drip nothing serious but I don't drive the rig yet so I'm hoping once I do start running it more it should stop,or at least slow some.I think they are prone to leakage LOL.

 

[GSP9]

I had my D20 comepletely rebuilt and the darn thing leaks like that,just a little drip nothing serious but I don't drive the rig yet so I'm hoping once I do start running it more it should stop,or at least slow some.I think they are prone to leakage LOL.

I have a 66 mustang too and they both sit in the same garage. Buddy of mine came over one day while both cars were parked outside. He took one look at the garage floor and said "Well, I know where the Bronco gets parked". Haha

 

[WILDHORSES]

It might sound like a dumb question but what is it leaking? Gear oil? I ask because i don't know if you are running automatic or manual trans. So as Viper said adapter to t-case leak. The thing with that is many times it's oil from the trans that is leaking there because a worn out seal between the two trans/t-case. In a really bad case you would know this by removing the fill plug of the t-case and oil will come out becuase oil from the trans is filling the t-case. If you are running a C4 you would be able to make the distinction with the fluid so my guess is it's manual trans oil or t-case oil. Either way if you want the leak to stop you most likely will have to separate the units. Good time to check and replace the double lip seal. Good luck! The Horse is with you.;D

Jim

 

[jdbronco]

It might sound like a dumb question but what is it leaking? Gear oil? I ask because i don't know if you are running automatic or manual trans. So as Viper said adapter to t-case leak. The thing with that is many times it's oil from the trans that is leaking there because a worn out seal between the two trans/t-case. In a really bad case you would know this by removing the fill plug of the t-case and oil will come out becuase oil from the trans is filling the t-case. If you are running a C4 you would be able to make the distinction with the fluid so my guess is it's manual trans oil or t-case oil. Either way if you want the leak to stop you most likely will have to separate the units. Good time to check and replace the double lip seal. Good luck! The Horse is with you.;D

Jim

What he said, when I first got my bronco running I checked all the fluids. 3 speed was low so I added fluid, went to the 20 and as soon as I opened the fill plug oil started pouring out.

When I swapped to the AOD, I rebuilt my t case with great determination to keep it from leaking and it still does. The fact that most of the bolt holes are drilled through into the case makes it very difficult to get it to seal. Just too many places to leak from. I have just resigned myself to having cardboard on the floor of the garage.

 

[GSP9]

It's a 3 speed manual. After I fixed the initial leaks, I added new fluid to the t-case (Valvoline 50w Racing Oil). The oil on the floor now appears to be that new oil but maybe this weekend I'll do a little checking. Where is the fill plug on the 3 speed manual and what oil does the transmission take? Maybe I'll stop on my way home and get some oil for it. Kind of curious now to see if the transmission oil level is low or not. Thanks guys.

 

[JB Fab]

If it's not leaking......It's empty

 

[jdbronco]

It's a 3 speed manual. After I fixed the initial leaks, I added new fluid to the t-case (Valvoline 50w Racing Oil). The oil on the floor now appears to be that new oil but maybe this weekend I'll do a little checking. Where is the fill plug on the 3 speed manual and what oil does the transmission take? Maybe I'll stop on my way home and get some oil for it. Kind of curious now to see if the transmission oil level is low or not. Thanks guys.

I don't remember what was used originally, someone else maybe can chime in. I ran gear oil in mine with no problems. I know the t-case is supposed to use 50 weight non detergent so maybe that's what originally went in the trans too?