medicmoose

So...after the first run of my truck I notice this morning that there is t-case oil on the floor and definitely some that sprayed around under the truck as I drove. It looks like a leak from the rear cover on the t-case. Is this something that I can remove and use some RTV to seal up while t-case is still in the truck or should I be looking at totally removing the t-case and getting a gasket kit?

millball

It depends on just where the leak is, and why it started leaking. RF1A right??

There are two pieces of the case that may be fairly easily removed with the case still mounted:: The small 7 bolt cover that can be removed after the output flange is taken off and the speedo drive gear removed,

And then the housing cover for the front drive drop, after the idler bearing snap ring is removed, held by 10 bolts, I think.

This about what can be done with the case still mounted on the tranny and in the truck.

medicmoose

Thanks for the help....I'm crawling under it now to see what I can figure out.

medicmoose

Okay...I got the first cover off....everyone take note of the one broken bolt

SO, to get the next cover off I just remove that c-clip on the bearing? Does the bearing come out? Anything I have to watch for (other than another broken bolt)?

Thanks for the help!

millball

You may be able to get the front drop cover off without removing that ring, but no biggie to get it off.

There are no small parts behind it to jump out, but the idler gear that bearing and snap ring go to can, and probably will, come free.

There IS a ball that might come out and get misplaced on that upper output shaft, if you pull off the speedo gear and the oil pump screw.piece.

You'd only need to pull those off to get to the rear output bearing; But, It might not be a bad idea to examine that bearing carefully for roughness and any slop

because now would be the time to change it out while the case is parted. That bearing is number 63/28 a common bearing.

If you clean the old paper gaskets off perfectly, then pass a flat file over the sealing surfaces of the cases to insure there are no nicks, and degrease with acetone or diesel starting fluid, you can reassemble with no gaskets using permatex ultra Grey, or similar.

28 or 30 foot pounds is right for those case bolts.

medicmoose

Thanks!

medicmoose

Okay...so the weekend project went really well and I seem to have been able to cure the leak. One question, the manual says that the capacity of the transfer case is 3.4 qts. I started to fill the case at the fill hole and it will only take 2 qts before it starts coming back out. I took it for a drive and checked again and as soon as I loosen the fill bolt it starts to come out so I assume it's full. Am I missing something....right now I am 1.4 qts less than what the manual says it should hold.

millball

If the oil is at the bottom level of the filler plug. It is sufficient.

95yoda

Not sure what manual says that but everything I read when doing mine says like 2qts. It's full when it comes out of the fill hole.

medicmoose

So the manual I have is the Haynes 92075 for Toyota Pickups 1979-1995. The capacities chart is what I was looking at. I originally filled it from the shifter opening when I had everything apart with 3.4 quarts. This is probably why I developed a leak! Anyway, now I know it's only about 2 quarts. I guess their line is right..."all capacities approximate"

I figured if it was in the manual it was pretty reliable...lesson learned.

Thanks for everyone's help!