[garage]

I have a leaky transfer case, and at this stage, finding it is coming out of the 'joins' or where I would imagine a gasket of some kind is (just guessing), does anyone have any ideas on what sealant would be good to use on this thing?

Thanks.

GO

[royce]

I like loctite ultra grey, seems to work well on those sort of surfaces.

as to aplying it, youll have to split the transfer

[garage]

I was hoping I wouldn't have too....
Hmmm... this is going to be more involved than I hope for.
My little truck has more leaks than the titanic!

[steve]

how bad does it leak? how much oil does it use?

my zooks leak from places, but i just keep topping em up

PS. or another transfer case will cost ya $100 ... that'd be an easy fix

[garage]

Well... lets just say I haven't been as good to the truk as I should be. Need to have a look and see the levels - otherwise... I know... I am up for big $$$ for new parts... The leak is mild, but I really should top it up....

[steve]

you don't need to spend big bucks. It's a zook, just replace the bits with other better second hand bits... doesn't cost too much.

if ya can't do it yourself, it costs a carton of beer to get your mates to help

[royce]

I'd give it a good clean and leave it for a bit, if its the case leaking you will get oil without driving it, if its only leaking when driving it might be a seal or the breather up the top has come out, much easier to fox

mines leaked out of the front seal for 5 years now, I'll fix it one day

[garage]

Looks like it is coming from a cable of some sort, that goes into the transfer case.... Anyone know what that is?

[garage]

I will see about taking a photo of it to show you...

[royce]

down the bottom towards the rear ? that would be the speedo cable, if you look under it you will see a 10mm bolt in the housing, undoing that will let you pull the cable out (oil will go everywhere so might be better to drain it 1st) and you will see the o-ring on it, you will need to get anther one of them and stick it back in, that should fix it

[garage]

Ordered the part - thanks for the help.

[garage]

Is there any cause for concern taking the cable out? Like, is it going to put things out of wack, need to be at a certain tension or lenght?
I have looked through the factory manual and my haynes, and both lack details on this operation... help!

[royce]

nope just undo the 10mm bolt, pull on cable and it will come out (maybe need a jiggle), if you dont drain the oil some will come out now.

then you will see the oring, just pry it off, slide the new one on, wipe a bit of oil over it to help it slip back in and slide it in, it should slide straight in but might need a jibble, then put the bolt back in (dont overtighten, easy to break)

if you were to spin the cable while its removed about the worst you could do would be to add or remove a few metres off the odometer reading

[garage]

Now I wouldn't want to do that now would I

[steve]

i've undone that bolt before and no oil has come out, I can't remember if i just left it in there by a thread or not.

Last time i did it, i didn't push the cable all the way in properly, so when i drove down the road the speedo didn't work. There's a bit of a slot on the end of the cable that has to slide in to connect with the bit inside the case.

[garage]

Dang! Tried to get the seal out and its stuck as! Even tried a fishing hook!
Anyone ever tried to get this thing out?
Chap at Suzisport said you could poke it out from the other side, but there is no other side to poke it out from unless you crack the case open? Ideas?

[royce]

the oring? stab it with something pointy and be more brutal

[garage]

Yeh, that is the one. When you take the speedo cable out of the transfer case and look in, you see a little rubber oring behind the speedo bolt thingy that turns the speedy cable... it's that thing... will true brute force!

Hey, ever had any trouble opening those damn filler plugs on the transfer case and transmission case?? I even tried heater the plugs and for the life of me, they refuse to open. Already broken a couple of ratchets on them...

[royce]

yeah the fill pugs are a pain if they havent been touched for a bit

a god tight fit on the bar and a hammer sometimes works

[antt]

my plugs are so rooted i have to either use a set of vicegrips, or a hammer and cold chisel to budge them

[royce]

my sierra I had to drill and easy out both fill plugs in the diffs, the front I didnt have a spare so welded a 12mm bolt in the hole

the vit ones were all nice and oose