LT95 oil migration from TC to gearbox

[nickj]

Hi all,

When oil is migrating from the TC up into the gearbox, is this the TC output shaft seal leaking?

If not, what is the resolution (I've already read about the balance tube hack, I'm looking for a proper fix)?

Nick.

[Phil B]

Hi all,

When oil is migrating from the TC up into the gearbox, is this the TC output shaft seal leaking?

If not, what is the resolution (I've already read about the balance tube hack, I'm looking for a proper fix)?

Nick.

Mine was the large spacer on the gearbox output shaft inside the tc. It should be loctited onto the shaft to stop it spinning. Thanks to Bearman.
This fix can be done without removing the gearbox.

[nickj]

Mine was the large spacer on the gearbox output shaft inside the tc. It should be loctited onto the shaft to stop it spinning. Thanks to Bearman.
This fix can be done without removing the gearbox.

Very interesting - can the spacer be accessed by removing the large plate on the base of the TC? Was there a thread anywhere on here with Bearman about the process or did he help you privately?

[Phil B]

Yes you take the lower access plate off and take out the intermediate shaft and gear cluster to get to it.
There are several threads on here related to this. The advise came from Brian (Bearman)

[Bearman]

Hi all,

When oil is migrating from the TC up into the gearbox, is this the TC output shaft seal leaking?

If not, what is the resolution (I've already read about the balance tube hack, I'm looking for a proper fix)?

Nick.

Gday Nick, The proper fix is to loctite the spacer and transfer input gear onto the rear of the mainshaft like it is supposed to be. To do this it is important that you firstly put the gearbox into 3rd gear and leave it there until you are finished the job. If it is a 4x4 you remove the round plate at the LH side top at the rear of the transfer case and then remove the snap ring and thrust washer and then the gear and spacer. Thoroughly clean it all including the mainshaft splines and then use loctite 609 on the spacer and loctite 648 on the gear. It you have a PTO winch you will haver to remove the chain first and if it is a 6x6 you will have to remove the 3rd axle drive first.

[nickj]

Gday Nick, The proper fix is to loctite the spacer and transfer input gear onto the rear of the mainshaft like it is supposed to be. To do this it is important that you firstly put the gearbox intop 3rd gear and leave it there until you are finished the job. If it is a 4x4 you remove the round plate at the LH side top at the rear of the transfer case and then remove the snap ring and thrust washer and then the gear and spacer. Thoroughly clean it all including the mainshaft splines and then use loctite 609 on the spacer and loctite 648 on the gear. It you have a PTO winch you will haver to remove the chain first and if it is a 6x6 you will have to remove the 3rd axle drive first.

I completely missed this post, which is a shame, because I ended up getting the balancer tube hack fix done while I was on the Sunshine Coast, rather than this proper fix... Thanks so much for the reply, I will see about getting it repaired properly at some point.

[mattmac]

Is there a tutorial preferably with some pics on this as need to do it myself after just did service/ oil change and discovered have oil migration from TC-GB:-(

[Phil B]

Bearmans step by step tells you what to do.
Once you drain the Tc oil and remove the bottom cover you will see what to do
When you remove the rear prop shaft and hand brake, remove the locking plate and main bolt the gear cluster falls out
Replace the rear output seal ( and flange if it’s worn) as well as the 22mm lock nut and felt washer while your are there
I had the diff reconditioned by KLR once I’d taken it out as well as new bearings and one new gear.
Note Bearmans comment on the main gearbox being in 3rd gear
If you don’t do this the spacer inside the main gearbox will fall out and that means a gearbox strip down to replace it!!!!!
Very important!!
Follow the rest of the process
It is fiddly but can be done from under the vehicle by one person
I’ve done it myself and I’m definitely not a mechanic!
Good luck