Help Urgent - Transfer Case Refill

[ShaunR]

Hi Guys,

I feel a bit ignorant here but I went to check the level in my transfer case today as it has a very slow leak. I made sure I knew what I was doing regarding the process. I have read the manual and also this link www.discovery2.co.uk / Transfer Box Oil change (http://www.discovery2.co.uk/transferbox_oil.html).

So I undid the filler plug to check the level of oil and as the plug released the oil came gushing out. By the time I got the plug back in I lost about a litre or more of oil. I definitely was working with the right plug located behind the handbrake cable but don't know why this happened or what to do now.

I have a litre of oil for the transfer case but am worried of losing more oil if I undo the plug more. I drove the car about an hour before doing this work.

Does anyone know why this would happen or what I should do now?

The car is on level ground.

Thanks,
Shaun.

[Bearman]

G'day Shaun, I you definitely removed the correct plug then it was obviously overfilled. Pull the plug back out and let it drain until it is at the plug level then reinstall plug. Then check the gearbox, most likely this is where the excess oil has come from.

[alien]

It sounds to me like it may have been overfilled, maybe to allow for the leak.

The Haynes manual has the level at the botom of the filler hole.
UP on the linked thread has 2mm over the lower edge.

If it was mine I'd allow it to drain from the filler plug hole behind the hand brake.

If it's a maual check the gearbox level also.
I'm not sure if the gearbox oil can get into the transfer box if the seals are gone.
On the auto it would weap out the join.

[ShaunR]

I thought that may be the case.

Is the oil for the gearbox the same as the transfer case then?

It is a manual.

The oil for the transfer case is CASTROL SYNTRAX UNIVERSAL PLUS 75W-90 and the manual transmission is CASTROL SYNTRANS 75W-85 .. That is the castrol brand anyway

[ShaunR]

Ok so I undid the filler plug again and there was still more oil coming out, so I did it back up as it was slowing down which would mean that it should be at the right level.

I am not sure how to check the gear box level. I have looked at the manual that I have and it gives a very close up picture of the drain and filler plug so I am not sure what I am looking for in the bigger picture.

Will it be OK to drive the car if the gearbox is now low in oil? The transfer case will still let more oil out if I undo the plug. All up I would say I have lost a bit over a litre.

Shaun.

[rick130]

If you are indeed undoing the fill plug on the t/case (it's almost tucked behind the parking brake drum) I'm guessing someone has filled it through the temp sensor plug in the LHS of the case high up.

It apparently happens from time to time.

The R380 g/box has a large hex plug low down on the RHS of the case facing the front driveshaft to drain, and a T55 Torx plug above and half way up the side of the 'box for fill.

Always undo the fill plug first, just in case you can't get it undone. ;)
An empty compartment without any way of filling it wouldn't be good :D

[alien]

Ok so I undid the filler plug again and there was still more oil coming out, so I did it back up as it was slowing down which would mean that it should be at the right level.

I am not sure how to check the gear box level. I have looked at the manual that I have and it gives a very close up picture of the drain and filler plug so I am not sure what I am looking for in the bigger picture.

Will it be OK to drive the car if the gearbox is now low in oil? The transfer case will still let more oil out if I undo the plug. All up I would say I have lost a bit over a litre.

Shaun.
The filler plug will be about 1/2 way up the side of the gearbox.
My book shows that a Torx 55 is needed(one of those star shaped tools).
By my picture it's on the front tail shaft side.

A short drive to a mechanic to check the levels should be OK.
I'll cover my self and say it's not ideal though.

[ShaunR]

Ah I know I don't have the tool to undo the gear box filler plug so I may get it down to a local mechanic and have them check the levels.

[greif]

I do not know if you have a td5 with diesel heater if you have it, I think your problem may be that the heat from it, or something else has melted the plastic into the vent that comes up on the right side of my it is left-hand drive so I do not know where they come up on your.
I do not think you have too much oil, but I think the air is tight so it has created an overpressure in the gearbox which is not good, it also tends to be a little sound hizzz
so I think you should inspect the venting after checking the oil level, I guess it hiss when you inspected it last time at the level cap? and that the oil is squirted out:p'transmission oil does not taste good, I've been there
Grief

[101RRS]

Ah I know I don't have the tool to undo the gear box filler plug so I may get it down to a local mechanic and have them check the levels.

An Allen Key may fit but the torx head can be bought from Supercheap, Repco etc.

Garry

[Roverlord off road spares]

We haven't eliminated the Gear box oil is not being forced into the transfercase via gearbox input. The seal at the rear of the gearbox could be leaking and as the gearbox has an oil pump the pressure is forcing oil past the seal and into the transfer??????
Generally it is pretty impossbile to over fill a transfer without knowing , as oil wolud bew pouring out of the filler hole, unless it was on a slope leaning forward and the rear was up high.

[rick130]

We haven't eliminated the Gear box oil is not being forced into the transfercase via gearbox input. The seal at the rear of the gearbox could be leaking and as the gearbox has an oil pump the pressure is forcing oil past the seal and into the transfer??????
Generally it is pretty impossbile to over fill a transfer without knowing , as oil wolud bew pouring out of the filler hole, unless it was on a slope leaning forward and the rear was up high.

Impossible.

There is a seal at the back of the R380, space (and a leak passage) then the input shaft seal for the t/case.

IMO the most likely scenario is what I described above, we've seen it before.

[bob10]

I would be tempted to do a complete oil change on both gearbox & transfer case, then start a checking routine of both, until you are sure in your own mind what is happening. Be a good idea to fix the transfer case leak at this point, Bob

[ShaunR]

Thanks heaps everyone. I think best bet for me would be for a mechanic to have a look as I have no experience with gearboxes etc if the seal is worn I wouldn't know where to start there. Hopefully I can get it there no problem.

[ShaunR]

Is this the gearbox filler plug and drain plug?




59025

[Alex 110]

Is this the gearbox filler plug and drain plug?
59025

yes. you need a big torx bit to get the filler plug out - I ended replacing mine with one from a series gb that had a square head as the local mechanic was getting the irrits at me always asking to borrow his torx bit

[OffTrack]

yes. you need a big torx bit to get the filler plug out - I ended replacing mine with one from a series gb that had a square head as the local mechanic was getting the irrits at me always asking to borrow his torx bit

Koken is a good quality Japanese brand.

SOCKET TORX 1/2DR - 60mm T55 - Koken (http://ozwidetools.com.au/torx-sockets-short/980-socket-torx-12dr-60mm-t55-koken.html)

I'm sure you can find cheaper ones on eBay if you don't want to spend $20 on decent tools.

I look at it this way: You are doing the job yourself because it is cheaper, and you know you'll do a better job than a bored mechanic. So rather than doing a "Bodgit & Scarper" job using the wrong tools and generally making a hash of it, spend a bit of what you are saving on the tools to do the job properly. You'll save yourself a lot of grief in the long run.

cheers
Paul

[ShaunR]

Cheers guys will get it sorted tomorrow for sure

[kelvo]

Impossible.

There is a seal at the back of the R380, space (and a leak passage) then the input shaft seal for the t/case.

IMO the most likely scenario is what I described above, we've seen it before.
I'm not so sure.

My transfer case level keeps increasing, and the gearbox level decreasing. I have drained and filled both correctly myself, yet the levels still change :eek:

My guess was the gearbox seal gone, then the pressure forcing its way past the TB input seal. I also have a leak from either between the GB & TB (Which would tie in with the GB output seal gone) or the intermediate shaft O ring.

Will be having a look once I get the time, along with changing the clutch release bearing, clutch, flywheel, injector harness, etc.....................

[rick130]

I'm not so sure.

My transfer case level keeps increasing, and the gearbox level decreasing. I have drained and filled both correctly myself, yet the levels still change :eek:

My guess was the gearbox seal gone, then the pressure forcing its way past the TB input seal. I also have a leak from either between the GB & TB (Which would tie in with the GB output seal gone) or the intermediate shaft O ring.

Will be having a look once I get the time, along with changing the clutch release bearing, clutch, flywheel, injector harness, etc.....................


Can't happen with the R380/LT85/LT77 and the LT230 t/case, too much air gap between compartments and has a drain between the two housings too, unless the drain between the housings is sealed up.

[BigJon]

, unless the drain between the housings is sealed up.

Possibly filled with silastic from below by someone who didn't know how to fix the leak (or couldn't be bothered). Then you could do the Toyota fix and put a hose between the two filler plugs for continuous circulation.

[lennymax]

yep when I first did mine I didnt see the proper fill plug behind the handbrake. I found the plug mentioned higher up on the other side and pumped in lots of oil..we learn from errors so when I found the correct plug it just drained to the right level.it seems your transfer has been filled from that higher plug..I put different quality oil in the manual gear box.:D

[ShaunR]

Had it checked by a local mechanic and both the transfer case and the gearbox are now at the right level. It would appear that the transfer case was overfilled and the gearbox was always at the correct level. Best case scenario for me. Thanks to everyone for the advice