[DieselBoy]

Hi folks, has anyone else had their transfercase throw oil out through the shifter boot??

As soon as I put the correct quantity of oil (900ml) in the case it throws the oil out while driving, until the level drops about 200ml below where it should be (I have measured ).

I stripped a spare t.case down to see if there was a seal under the leaver, there wasn't on that t.case, and my workshop manual doesn't actually show an exploded diagram of the shifter arrangement which is unhelpful.

I'm sure this can't be just exclusive to my LJ, and I am going to pull the shifter leaver today for a look on the t.case that's on the truck, but until then anyone got any fixes for this??

Worried the top bearings in the t.case will run dry one day.

Cheers,
Pete.

[Gibbo]

I had the same problem, my guess is its to much oil so i just let some drain from the oil level screw and its been ok since.

[DieselBoy]

An oil Level screw??

Right, back to the manual to see where it's located!!!!

[fordem]

The way it works (or is supposed to work) is that you fill the transfer case until the oil overflows the fill hole - the fill hole is also the level hole.

[Gibbo]

DieselBoy wrote:

An oil Level screw??

Right, back to the manual to see where it's located!!!!

Oil level screw towards the front of the car near the uni/shaft

[DieselBoy]

Cheers for that Gibbo, I have both the LJ50 and LJ80 work shop manuals and never spotted that.

What a muppet huh

[DieselBoy]

Also while I have the attention of the LJ crew, I just had a bearing kit fitted to the gearbox and one of the last jobs when reinstalling the engine and box is to fit the intermediate shaft to the box. It was then I noticed the rear output seal had been fitted the wrong way round.

I finished the job anyway, and yes it leaks like a bastard

I have the seal dimensions and all that sorta stuff, what I want to know is has anyone had any luck getting that seal off the shelf from a seal supplier or is it a Suzuki special??

It's a funky little seal, and I was really pissed they farked it up, I chickened out of doing it myself and payed $500+ @ $90p/h for them to do the work. They offered to sort it out for me but I've lost faith in them and I don't want them anywhere near my precious LJ80 hahaha.

It'll only take me half an hour to fit the seal, and cost me a seal and a beer or two