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Old 11-11-2013, 05:34 PM   #1
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T=Case leaking

Ok, Had the CJ in the shop to replace the rear output shaft seal=Dana 20. Turns out the yoke was scored pretty good so that was replaced.

Now I am having leaks like a stuck pig from the bolts. And it looks like the vent tube and possibly the speedo cable.

Tightened the bolts up, but still leaking from the vent tube and speedo area. And possibly the bolt right by the speedo. Talked to my shop and of course they said bring her back. Will over filling the T-case cause this ??

And now the rear pinion seal is leaking, well oooozzing just a tad. Great so now that gets to be replaced tomorrow

Anyway, what gives with the leaky T-case ? Any thoughts or clues ?? It was not leaking from any of these spots post replacement yoke.

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Old 11-11-2013, 05:45 PM   #2
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could be overfilled but to me it actually sounds like it is not venting..If the vent is plugged,then as it heats up from running it builds up pressure and leaks from everywhere it can

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Old 11-12-2013, 08:09 AM   #3
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HHHmmmmmm that makes perfect sense. Can the vent be un-plugged easily ?
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Old 11-12-2013, 08:22 AM   #4
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I wouldn't think so but it could easily get plugged...insects,mud,crude,whatever
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Old 11-12-2013, 08:41 AM   #5
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GREAT !! Well it is headed back to the jeep hospital. I'll update later,,

And thanks for the information HD
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Old 11-13-2013, 08:07 AM   #6
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I wouldn't think so but it could easily get plugged...insects,mud,crude,whatever
Ok, I was intrigued to see if I could locate the issue. Tightened the bolts around the output/yoke. Drove her around to warm up the fluid. When I crawled under it looks as if there is some seepage around the speedo cable attachment and don't laugh- the vent tube was wet.

dang it.
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Old 11-16-2013, 08:54 PM   #7
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The secret to rebuilding a transfer case so there are no leaks for a long time are as follows. Its been a few years but here goes:

Don't replace the yoke. Get a speedie sleeve. It will be better than a new one. It will have a groove in it, it will leak if you don't sleeve it.

On the inspection cover, hammer the holes flat on an anvil. It wont hurt to dimple them from the inside with the dimple toward the bolt head. Check on a piece of glass with sandpaper taped to it. You will want it as smooth as possible with any dimple facing the bolt head.

On the felt seal, use permatex brush on gasket sealer on the outboard end to keep oil from leaking out.

Chase all holes in the casting. Do not use a tap, use a thread chaser. Taps will wear down the threads.

One the input shaft, use a new bushing and drill a hole through the bushing that matches up with the hole in the outer shaft (Model 18)

On the endplay. If the manual says .008-.012 endplay, shim it to .005 or less. Reason being thermal expansion, wear and run in. Use gasket sealer (thin coat) on both sides of the shims. Use gasket sealer on the mainshaft ends where they enter the case.

Most of this is for a Dana 18 but some is usable for a Dana 20.

I never used silicone sealer for anything. It will fail and leak. Guaranteed.
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Old 11-17-2013, 09:40 AM   #8
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Originally Posted by Tahoe View Post
Ok, I was intrigued to see if I could locate the issue. Tightened the bolts around the output/yoke. Drove her around to warm up the fluid. When I crawled under it looks as if there is some seepage around the speedo cable attachment and don't laugh- the vent tube was wet.

dang it.
no doubt that I have removed jeep speedo drives but its been so long that I don't remember anything about them..I do know that on older chevys there is,what they call a bullet that the gear sets in..this bullet has an o-ring on the outside and the inside that can leak..also the gear itself can become worn and cause a leak..I think I would probably take something like weed eater string or a long tie strap and run it in the vent tube to make sure it is clear
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Old 12-06-2013, 10:00 AM   #9
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Update- Looks like a simple over fill issue on the T-case. And the O-ring does need to be replaced. The "leaking" is now just a wet - seeping around the speedo cable. I'll deal with that when we get out of this cold snap, Down in the 40's and its cold (at least to me)

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