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joshuasv 05-09-2008 08:37 PM

Transfer case overfill.
So, since day one my transfer case has had a small leak. The drain plug on the transmission leaked also, after cleaning that up and fixing the leak I found that the transfer case was leaking. I don't know where from, but is definitely leaking. Today while changing the oil I decided to check the level in the t-case, to my surprise the minute I take out the fill, level check plug, fluid starts pouring out. I had a sneaking suspicion that it might happen and was able to keep the mess to a min. My question is after this long lead up is; will it be bad for the t-case if i leave the excess fluid in there? Am I correct to assume that the leak may be caused by the excess fluid?

jpdocdave 05-09-2008 08:51 PM

yes overfilling is bad. lots of guys over fill this stuff, its worse on differentials though. people shove fluid in, and cap it off right away thinking more is better. then the axle seals leak.

i don't know what it could do to the t case though. is it leaking by the rear output shaft seal? where the rear drive shaft exits the t case. thats common, and could be a result of too full. or there's a seal between t case and trans.

i'd say now that its not over full, clean it up, and keep an eye on it.

joshuasv 05-09-2008 08:57 PM

The output shaft seal is new. Previous owner installed a SYE kit, probably overfilled it then. I actually haven't found exactly where it is leaking yet.

spanky 05-09-2008 09:33 PM


Originally Posted by joshuasv (Post 227623)
The output shaft seal is new. Previous owner installed a SYE kit, probably overfilled it then. I actually haven't found exactly where it is leaking yet.

same problem on mine. previous owner installeda SYE and now the transfercase is leaking. dont know if it was caused from over filling or poor workmanship installing the new seal.

regardless im having a new tranny and clutch put it, having him look at the transfercase as well, gonna seal it correctly. should take care of the problem!

joshuasv 12-24-2008 12:46 AM

Update on this situation.

So apparently there was a leak between the NV3550 and the transfer case which was causing the the transfer case to be overfilled by the transmission. Tho not visible from the outside as I could see no evidence of a transmission leak. The down side to this is that I now have a burned up nv3550, with only 12,000 miles on it. Merry Christmas to me!

I am told the cause could be from not replacing the input shaft seal on the transfer case when doing the SYE kit.

Previous owner is also curious as he is the one who installed the new transmission and the SYE! :mad:

Anyone hear of this before, or have any experience with such failures?

jdhallissey 12-24-2008 01:11 AM

Well don't call the tranny a waste yet. Fix the leak first then refill your tranny I bet your fine actually

joshuasv 12-24-2008 08:50 PM

Unfortunatly its already in the shop as I lost every gear except fourth. By burnt up I mean input shaft, output shaft, teeth ripped off of gears on gear cluster! It made no noise before letting go, except for the minute before letting go.

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