Thursday, May 21, 2015 at 12:10
Geoff,
I first heard about the oil transferring "uphill" from the transfer to the gearbox and experienced the phenomenon quite a few models ago. It appears that as the tc and gb heat up the oil is pumped by the pressure in the tc overcoming the seal for the gb on the main shaft. As the oil level is higher in the gb as compared to the tc the lip of this seal is positioned to keep the oil in gb. Being a single lip seal as standard it doesn't take too long for the oil to overcome it. A double lip seal, as used in the later automatic Cruisers does prevent this, but of course to fit requires some dismantling which can be a bit onerous if all else is good.
This is where the hose between the filler plugs does the job of keeping the tc from running dry while the gb over fills. I'm not sure if it is just a matter of giving the oil a pathway to return or whether it is more about not allowing excessive pressure buildup. My opinion is that it probably is a bit of both.
I found out about the main shaft and tc gear spline wear when I noticed a fair amount of tailshaft backlash developing on whichever car I had at the time. Further investigation by removing the PTO cover on the side of the tc allowed me to determine that the backlash on the mainshaft was getting quite bad and that
the nut in question was loose. Tightening
the nut helped but of course couldn't cure the spline wear so it soon came loose again. A complete strip down and parts replacement was in order, so I have always kept an eye on the tension of this nut ever since. As you may have observed, this isn't too hard. Just a removal of the cover behind it.
The Cruiser that the mate had when we did the CSR trip many years ago required one of the modified longer spline tc input gears because the spline wear was getting way too bad to trust it for such a trip.
Whether the noise you are getting requires further checking is of course up to you. Personally I would get it checked out. I have seen a couple of the earlier transfer cases fail where the idler gear between the tc input and front/rear drive runs on a hardened shaft. From memory they had double row needle bearings but as this shaft is prevented from rotating it wears on one side only. Easy enough to change the shaft and bearings if caught early on. Caught early enough and usually the gear bearing surface is OK to go again. Catastrophic if left until it fails.
Cheers
Pop
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