I have had two dual cases in my '85, neither have leaked anywhere. The original one was installed at Marlin's shop, the 2nd one was built at Marlin's shop and I installed it. Have you tried snugging up the bolts that hold the two cases together?

 

To be honest, I havent tried much aside from attempting to seal it up where I thought it was leaking.
This, apparently, is not sufficient. Ill be contacting Bruce and go from there. But I'm going to try and contact Marlin before they close for the weekend and see what they say.

Thanks for the advice guys, I appreciate it very much!

 

Ok, just got off the phone with Rocky down at Marlin's shop. He said that if I want to try and fix it myself, it will NOT void any part of the warranty. So if I do try this (with Bruce's help) and it doesnt work, they told me the turn around time for getting it fixed would be the same day. So basically I could drive it up and have it there by 8am and drive it home that afternoon.
Decisions decisions...

Ha maybe I can make this a poll and see who would take it up and who would attempt at fixing it on their own.

What do you guys think? Basically all that I have to do is pay for gas and get a friend to go up with me.

 

while i realize there's no guarantee you can fix it on your own, i say give that a shot first. bruce knows his way around these things and should be help you stop the leak. and if it's just some rtv you have to buy, that's not too much out of your pocket. if that doesn't work, you always the plan b of going up to marlin.
this way you'll gain some wrenching experience and technical knowhow that will most likely help you down the road. plus, that means a whole lot less driving for the fix. and shoot, then we might as well go wheelin

 

Ditto charles.

 

as long as I don't need to take the crawlbox apart, and just take the transfer case off to reseal it, it should take only a few hours to do. I have RTV, so all ya need to do is come by.

 

well, it depends. the leak seems to be coming from the back side of the front adapter (tranny to front case). Basically it's the seal between the adapter plate and the case.
Looks like it might take a bit longer...

 

How early on sunday morning can you make it by? We'll need some gear oil, since it looks like the case needs to come apart.

 

10am early enough?

I'm planning on dropping the front driveshaft, skid, and drain the fluid today to make things move a bit quicker tomorrow.

 

Wait, are you planning on driving it with no gear lube in the front case?

 

the front shaft isnt spinning when in 2WD, oh jeez Im going to sound like a retard if I'm not supposed to do this. I didnt know the front case even had gear movement when in 2WD.
Good thing I havent done it yet

 

Front case in high range is 1:1 gearing, not direct drive, though.

 

meaning what?

 

I guess to clarify this, there are parts moving inside the reduction box even in high range, shafts, bearings, etc. If you doubt this, feel the base of the t-case shift lever after driving at high speed down the freeway for a few hours. It'll be almost too hot to touch, especially w/ dual cases and in hot weather.

 

gotcha, no draining and driving then.

I feel like an idiot, I should know these things by now

 

Mine does not leak anymore, but the 5-Speed still looses gear oil level to the chain case, not the gear case which is right next to it.

I have no clue why and I don't care anymore, it seems to work fine the way it is.

The gray stuff works better to seal the crawler than the Toyota Orange stuff.

 

Ive got the gray stuff.
My problem is not losing oil from one place to another contained in the entire unit itself.
Mine is physically dripping out and leaving it's mark wherever I park.

 

10 am will be fine, see ya tomorrow......

 

Don't forget to take pics!

 

cool, see ya then!


camera will be with me. Ill post pics if I have something worth while to post.