I recently got the t-case from beard but anyway it leaks persistently out of the front I do believe. I have replaced the seal, and the actual front to the case that holds the seal in place from my other t-case and it just leaks all the time when driven not a slow leak but a fast one. Anyone have any suggestions?

 

It could be your transmission rear output shaft seal.

 

I dont think that it is, checked the tailshaft earlier and it looks alright.

 

I used rtv for the tailshaft to tcase. I always noticed it was wet but it was never low on fluid. Did you make sure to clean the surface well?

 

the input shaft seal on the case is notorious for leaking, the trans fills the tcase overfull and it leaks. pull the fill plug out and see if fluid comes out, if it does that seal is bad. is the vent clogged?

 

nope the other t-case i had in there never leaked so i know the vent isnt clogged it could be but i doubt it, and yeah the trans isnt leaking tested that today. I scraped the surface off and put on a new gasket. It still leaks out of the front seal although I dont know why. I talked to a ford mechanic and he couldnt tell me anything that was much of any use just confirmed what I had already suspected. Although I am gonna put the original seal housing back on there with another new seal. But I forgot to mention that its a fast leak when just turning in 1st gear at 900 rpms, when I drive it and put it under stress it seems to fly out at a higher rate.

 

i meant the vent on the t-case, check that and see if it is clogged. is the tcase overfull? is it leaking out between the tcase and tailshaft mating surface or where the front driveshaft comes out of the tcase?

 

It leaks at the mating surfaces at the tailshaft and the t-case. It might be the output shaft to the trans. thats damaged im gonna take it out and look at it tomorrow but its def not the seal it has to be something else. I have thought about putting "oil treatment" in it so that it cant leak out due to being to thick its the thickest oil ive ever seen and at 25 cents a quart. It might be worth it.

 

dont do that it will destroy it.

so you checked the input seal on the tcase? that spring seal?

also you added fluid to the case right?

 

Sucks man. . . . sorry.

 

Yeah I did both of those I have had 2 new seals in it so far so its def. not the seal. im gonna put in some fluid that isnt so light as atf maybe some thicker gear lube but not that stuff if it will damage it.

 

DO NOT PUT THICKER OIL IN THE TCASE OR IN THE TRANS

have you replaced the seal in the tailshaft housing of the trans? the only two things that could cause it to leak where it is leaking are the tailshaft seal and the transfercase input shaft seal. the area between the two seals should remain dry. the tailshaft gasket is really only needed on auto trans trucks

 

well i put it there for safety measures and the trans doesnt leak it has to be the the t-case, i have tested just about everything its very hard to figure out why it has such a bad leak.

 

i always use a gasket whether its an A/T or a M/T. my trans was leaking between the trans and tailshaft housing/ after i sealed it up twice, i found a hairline crack in the trans case and repaired it from the inside. take pics of the leak

 

the output shaft from the trans was wet so its coming through the input shaft from the t-case.

 

are you sure you mounted it up correctly? it didnt leak at all like this for me.

 

yup all 5 bolts to mount it up were in nice and tight, but i replaced the output shaft from the t-case and im pretty sure that is going to get it to stop leaking, b/c the shaft coming outside of the trans was wet at the tip going into the t-case but only the tip.

 

alexander coming from experience stop driving the truck until you get it fixed. i just kept pouring fluid in the trans for a week til i got time to fix mine(same problem) and i burnt my transmisssion up FAST.

 

mines still fine knock on wood. If it leaks i may try some epoxy mixed with atf to see if it fixes it

 

I have not driven the truck but all of the preparations have been made to accompany the 1354m the driveshaft and everything. I even removed the old electric switch and I have substituted another input shaft out of one of the other t-cases that I have as to the leak that I think it has in it so hopefully I will get it up and working tomorrow.

 

is there a possibility the tailshaft or the input side of the new t case is tweaked a bit and not flush up against the other side of the joint? just a thought that could be the culprit

 

Well on the output shaft of the t-case there is a metal backing in about 2 inches or so and i think that this might be damaged somehow. It doesnt appear to have any thickness in it when I measured the length of the shaft itself.

 

I fixed it.

 

This leaking t-case has been a real bear. I removed and reinstalled the case five (5) separate times, each time with a new modification. So far, I've changed the front seal twice, the front input shaft housing twice, (a new seal in each of the housings), and finally the change which appears to have solved this persistent, nasty leak, the input shaft from the '98 case was installed in the '93 case (with a new seal, of course).

Two events made me suspicious. First, the output shaft splines on the transmission where it connects into the input shaft of the t-case was "wet" with fluid approximately the same length as their mating surfaces, and (2) I put ATF into the hollow of the t-case input shaft and it simply leaked into the case. I also thought to install the 6 planetary system into the '93 case, but the depth on the reverse side is different on the 6 than on the 4.

The transmission output seal did not leak, and the breather tube has been unclogged the entire time with the exception of the first attempt, which included a drive of less than 2 miles.

 

2wd no transfer case FTW!

Just kidding, glad you got it fixed