Biggest Transmission Leak Ever !!!

[CJPilot]

[size=12]Well so much for my almost leak free rebuild of my transmission and transfer case.�I had been warned they all leak a little. I though I was in good shape.� I rebuild everything about 9 months ago they have had gear oil in them for about 6 months with no leaks. Now mind you I have only run the engine and had not driven the Jeep until today.� I drove it maybe a half a mile if that.� After parking it back inside I noticed a puddle under the Jeep. Rats!


It looks to me like the mating surfaces of the transmission and transfer case is not sealed or maybe it's running down from somewhere else.

I put a wrench on a few bolts and they where tight.

This is a shot of where the transmission mates to transfer case. So any ideas what I screwed up?




Steve
[/size]

[F Bill]

Do I see a gap at the junction of tranny and transfer, directly underneath your bolt?  You might have a part in the wrong place holding the two apart........and still have tight bolts.

[CJPilot]

[size=12]Bill � It does look like a gap in the picture doesn�t it?� I�ll check it out in the morning.

Thanks,

Steve


[/size]

[bretto]

It could be the locking plate for the counter shaft out of place on the tranny is not in the pocket of the transfer case properly.  Its happened many times.

[Carls_jeep]

Some gasket sets have several different thickness gaskets for there. I seem to remember that the spacer ring between the two cases sticks out from the rear surface of the tranny case and you have to use the right thickness of gaskets to fill that space plus a few thousandths to make it seal there. I remember measuring how much the ring stuck up and then using a little thicker set of gaskets to make the seal between the two cases.

[CJPilot]

Thanks Bretto and Carl.� �I think you guy�s are on to something.� I pulled the tub this morning to get a better look.�
To be honest I don�t think I paid much attention to it when I installed the transfer case.� Silly me




Steve

[CJPilot]

[size=12]Bingo, I think the problem has been located.



The lock tab has cut the gasket, indicating it is if fact out of position

Steve
[/size]

[bretto]

Yeah!
Glad you got it figured out.