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Has anyone ever had this happen?

I had the same over fill problem with my transfercase in my 92. I have the nv4500 transmission in it and that uses the gl-5 gear syncromesh fluid. So my transfercase was getting filled up with the gear lube.

Not a big deal to change that seal. I think I just took the rear driveshaft off and the front drive shaft off. I had to cut a wrench in half to get at the top bolt on the transfercase because there wasn't enough room to get the wrench up in there.

Getting it out wasn't that bad. The transfercase is alittle awkward and heavy and putting it back on the shaft was more of struggle. My arms got tired trying to get it back on the splines. The seal was only acouple of bucks. I think I also bought the gasket where the transfercase mounts to the transmission because mine tore in half when I took the transfercase out.

You should be able to tackle this job though. My seal had three hairline cracks in it.
 
I drove it today and after warming it up I checked the tranny fluid level and it was above the full line. I´m gonna drive like this for a few days and see what happens. If the P/O had really overfilled the tranny could this have forced fluid past the seal to the T/C?

Handcannon- I like that idea I´ll have to get under and check out the tranny fill. Thats if this keeps happening.

Doober- If it keeps happening then I´m gonna give it a go. I hope not though.

Thanks g
 
Gnel,

I Just replaced that seal on my '94 gasser (4l60 and NP 241C). We were doing a routine fluid check and oil change, Tcase POURED from the fill hole. Jamie goes "let's jerk i t out" Haggar is going "top off tranny and wait for warmer weather...." But Jamie was right. So we did.

It took about 3 hours to pull (but we were piddling with other items too, identifying a PS leak and rear pinion seal.) I also had the truck wrong on the lift..( couldn't get the cross member bolts out. and couldn't get the cross member out)..so we fought a few things we didn't need to. The front drive shaft flange would not release (rust) so we took it apart at the splines, which made it grab stuff weirdly. (don't pry the flanges apart, or if you do, file the surfaces to be flat again. Never-seize before reassembly)

I had about 1.5 hours r&r ing the seal with Tcase on the floor. ( you will need 2 "gaskets" and the seal. the gaskets are the tranny to TC adapter (in mine it was a "square" o-ring) a paper gasket TC adapter to transfer case) The seal is in the front bearing retainer of the TC. Seal puller will not get it. take the retainer off, push old seal out and new one in. clean up old rtv. apply new RTV. Anerobic seal all bolt threads. (cleaning off the GM bolt sealer took just about the most time) Cleaning old paper gasket from TC adapter did take a long time. torque everything back properly. BE CAREFUL, you do not want to get dirt into either the tranny OR the TCase. Loose gasket junk is just as bad..

Putting it back in was MUCH smoother. We repositioned the truck so we could get the cross member out. Much easier. You can do it easily in one day. Just have all the parts you need before you start.

GL, HTH

Haggar
Edit was to break up paragraphs.... sorry it was one long one.
 
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Haggar,
Thanks for the detailed procedure. I´m gonna wait and see like you were going to. I don´t have a Jamie to motivate my lazy butt. g
 
LoL!!!

I totally understand... It is nice to have it done, but it was almost surreal when the wife asked why the 'burb was still in the shop for an oil change and ps pump fix.... Dear, the transfer case is on the floor...

all in all not too bad. We went ahead and changed the tranny fluid and filter. When I dropped the pan there lay the filter and bushing.... First time I had seen it on the 700/4l60 s. seen it on the Ford AODs just not the GMs. So, I am going, what would have happened if I had not changed the trans seal, etc. Was it a sign? I don't think one had anything to do with the other. The Seal was split in 4 places and hard as a rock (had probably been doing it for awhile). So I lucked out I think.
 
Acesneights1 said:
Drain it to an acceptable level, make sure trans is full and monitor it. The leak may not be that bad. Who know's when the last time anyone even checked it. It's not uncommon to find that. Transfer cases hooked up to Manuals AFAIK use gear oil. I believe it was donethis way incase the seal fails the tranny won't get contaminated.
Click to expand...

My NP208 behind my blazer SM465 uses ATF. Trans is open at the back, T-case has a front seal in it.
 
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