Leaky Transfer Case After 4wd

Hi All,

DISCLAIMER: I'm a complete Jeep newbie, so please bear with me here. I appr

I recently-ish picked up a '57 CJ5 that we think went through a rebuild sometime in the late 80s. Today I took it for a drive and after wanted to investigate the 4WD function of the Jeep. I went to a parking lot, put 'er in N, flipped the bars on my Dualmatic hubs (this wasn't easy for the passenger side hub) and then went to shift into 4WD following Derek Redmond's instructions for Jeeps with two transfer case levers here:

I don't think this Jeep has been put in 4WD mode for a long time--it was difficult for me to engage 4WD mode and so difficult for me to get into 4WD H that I don't think I was actually in 4WD H. In the moment, I thought I was in 4WD H (but looking back I think I may have been in 4WD N) and I drove fairly slowly around the parking lot a couple times. I could feel a difference when there was power to the front wheels versus driving in 2WD mode. After that I got out, flipped the hubs back, disengaged the 4WD (or so I thought) and scooted back to the house.

When I was pulling into my drive I could smell something burning--at first I thought it was the clutch burning at which point I started seeing smoke. I pulled in, turned off the Jeep, opened the hood and found the Jeep was smoking from underneath. I went under and discovered there was oil in and around my transfer case and that the oil was running onto my clutch which was causing it to sizzle.

So, all that being said a few questions:

1. Does anyone know what was going on/what may have happened?
   
2. I confirmed (for sure this time) that the Jeep is back in 2WD mode with the transfer case lever in N mode. Am I good there or is there some way that I should be properly resetting the transfer case back in to 2WD?

I cleaned off the oil from the bottom of the transfer case and it does not appear to be leaking anymore--perhaps it got hot causing it to expand a little and leak?

I appreciate all your help and expertise in advance!

 

There in no neutral on the 4wd shifter. The lever closer to the driver is either 2wd (forward position) or 4wd (rear position)
The lever closest to the passenger is for low range (forward) neutral (middle) or high range (rear position).

 

I'm having a difficult time imagining how transfercase gear lube could get into the clutch. I would assume there is a T90 transmission in between. You are not referring to the drum on the rear of the transfercase? That is the emergency brake drum and should never get hot enough to sizzle unless left engaged while driving-something you don't want to do.

The usual D18 leaks are the output shaft seals, both front and rear. When the rear leaks, it most definitely lubes the brake shoes in the e brake drum. Now that you have it cleaned up, take it for a SHORT drive and see if you can tell where the leakage is from.

 

Roger! Yes this is what I meant to say. Confirmed I am in the correct positions.

 

Ah I believe you are correct—what I was looking at was the e-brake drum (slightly embarrassing)! Tomorrow I will confirm that the e-brake is truly disengaging and then take it for a short drive, check for leaks, and report back. Thanks!

 

If the jeep sat for a long time the seals likely hardened up from age.
4wd on pavement can cause driveline damage and issues engaging and disengaging 4wd.
The way these work you need a very slight rotation to engage the front driveline if it doesn't want to go easily (same with the hubs).

Replace the seal with a dual lip or double up the thin replacement seal and order new parking brake shoes. Check the rear flange on the transfercase for groves where the seal rides. Make sure you don't overfill the transmission as it overflows into the transfercase via an internal vent (and also out the front into the bellhousing)
The Trans is more likely to leak if it is overfill.

All that said... mine leaks and my Australian Shepard is just the right height to rub her back on it.

 

This. Also the jeep will act squirrelly as the drivetrain gets into a fight with itself. You may need to reverse a few feet to dis-engage 4WD.

There is a "neutral" on the two-stick transfer case, it's between Hi and Lo ranges, not on the 2WD/4WD stick.

 

Oye, no more pavement 4WD. I’ll give it a good reverse tomorrow before I leak check the transfer case.

 

Okay confirmed the e-brake can disengage and doesn't appear to be rubbing. Took it out for a short spin and looked underneath--it looks like this seal might be the culprit.

 

The speedometer cable connection at the top of your photo is also a known leak point.

 

Wow, that pan looks suspiciously clean and new.

 

I noticed this too—that’s why I wondering if perhaps I overheated the gears in there and it caused some sort of expansion leading to a leak. I’m nearly 100% sure it was not leaking before I messed with the 4WD as I’ve never seen any oil dripping (miraculously) under the Jeep until now. I haven’t put a wrench on those bolts yet to see if any are loose—perhaps that’s a good place to start keeping in mind what Glenn said about over tightening.

 

The smoking is definately not normal. I agree maybe the brake is set too tight. Its much easier to shift the t- case when rolling slowly.

 

That would be running down the rear bearing retainer. Nothing obvious there or out the rear seal/shim pack. It probably is the pan gasket but check the front bearing retainer (housing the shifters mount to) bolts too.

 

Okay so it appears as thought some of the bolts on the pan were a tad loose. I tightened them a hair, took it for a test drive and no more leaks. I will check again tomorrow however, the oil that was leaking out didn't smell the best--perhaps it's a good time to change the transmission and transfer case fluid?

 

Hypoid oil smells horrible even when new from the jug. If yours is still amber colored and no metal sparkle in it, its fine. If the oil is real dark, almost black, it need to be changed.
-Donny