transfer case leaks

When you put your transfer case onto your transmission Does the bearing adapter go in after the transfer case is bolted up.to the transmission? Or can you put the bearing adapter into the transmission and then bolt up the transfer case? The reason I'm asking is i put the bearing adapter into the transmission and put the transfer case on, and it leaks like a sieve between the two. it appears the two are not mating up tightly. I have not been able to find any reference..Help

OHale
67 CJ5 '77 231 V-6 T-86 w/ D18

 

The bearing adapter goes onto the transmission first. That is what supports and centers the transmission output shaft and centers the transfer case on the transmission. Did you install a gasket between the transmission and transfer case? On a T-86 there is no other seal between the transmission and transfer case other than the gasket.


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Yes,I put put the bearing adapter into the trans as i felt this was correct. I then put on gasket coated with copper coat sealer. when i started to fill trans and transfer case oil started leaking from between the two. It seems the two are no mated well. i have just read on another site that the locking plate sometimes needs to be trimed so as not to interfear with the mating. after I cool down a bit i'll pull it down again and check that. I just hoped someone had a magic answer for something i did wrong. thanks oren

 

Mine was leaking for a long time. I found when I originally installed the transfer case I broke the gasket. After the rebuild, and being careful. It now doesn't leak.

 

Using studs to guide the transfer case into place helps keep from damaging the gasket like Scott said. I had to learn that the hard way


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If you have the SM 465 Novak adapter. You can't use studs to guide the transfer case into place.

 

You can use one. The bolt that threads into the transfer case can be replaced with a stud. In fact that's what the factory did on CJ's with factory T-18's


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That's what I thought. If I use a stud in that location I could keep all the oil from draining out of the transmission. So I tried it, with no luck. Seems you have to put the transfer case front output housing into the side pocket of the SM465 first. Then rotate it onto the adapter. If the short stud in there. You will not be able to do this.
It really sucks having to drain a gallon of gear oil, because of one little bolt.

 

Wasn't aware of that. Have never run into that. Moot point as the OP doesn't have an SM-465 so how does it affect him?

To the op OHale, you might try slipping a feeler gauge between the transmission and transfer case while still bolted together. It "might" tell you if there is a gap indicating something is holding the two apart. No way should you be able to force one in. Regardless the transfer case needs to come off but it might help find the problem before taking it apart.


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THANKS, THE FEELER GAUGE IS SOMETHING THAT I'LL TRY. I WAS JUST HOPING THAT THIS IS A COMMON ENOUGH PROBLEM THAT SOME ONE COULD SAVE ME SOME AGRIVATION . THIS IS THE SECOND TIME I'VE PUT THE TWO TOGETHER WITH THE SAME LEAK. THE GOOD LORD MADE IT LEAK THE FIRST TIME AS I HAD JUST REBUILT THE TRANSMISSION AND I KNEW I DAMAGED THE GASKET PUTTING THE TWO TOGETHER. WHEN I PULLED IT BACK APART I FOUND TRANSFER CASE GEAR DAMAGE THAT I HAD NOT LOOKED AT PRIOR. ITH INTERMEDIATE SHAFT WAS EATEN UP CAUSING THE GER TO **** AND EAT UP THE OTHER GEARS. I THEN REPLACED ALL THE GEARS AND WENT WITH THE A.A. INTERMEDIATE BEARING KIT, AS I ONLY HAD ABOUT 250-300 MILES ON THAT REBUILD. McRUFF MACHINED MY NEW INTERMEDIATE GEAR AND IT WENT TOGATHER VERY EASILY. THIS TIME GUESS IT IS JUST MY HASTINESS TO GET BACK ON THE ROAD.
THANKS EVERYONE FOR YOURHELP

 

Well, i did what Nickmil suggested, feeler gauge indicated about 12-15 thous gap. I pulled it apart and I had installed the locking plate on the transmission from the bottom instead of the top. Had to trim it down to clear the bosses on the transfer case. It then went together easily. Funny how things screw up when you get in a hurry. Again like to say thanks for all the suggestions.

oha