Thread: Low transfer case oil=rear diff failure??

Originally Posted by trevor

Hey all, I was adding a transfer case sump today and when I drained the oil (supposedly 2 liters give or take) about 200ml came out :0. Last month my rear diff blew and the warning signs have started again. I am currently waiting for a new rotoflex and bush so can't exactly see if this fixed my issue. My rationale for why it may cause the diff to go is: the transfer gears are very strong and unlikely to break so it continues to give power to the prop shaft which is not as strong but stronger than the gears in the rear diff which give way eventually. Is my reasoning logical or am I looking for reasons as to why my diff keeps having problems. I will attach pictures when I get to a desktop.

Sounds like there are a few issues Trevor,
Do you make sure in your services that all oils are changed and at the right level???

I don't see how the low oil level in the transfer box would effect the rear diff. The rear diff has it's own oil level. The transfer box should still be transfering power from the gearbox to the diff via the rear tailshaft. I don't believe the method of transfer to the rear diff would change due to the low transfer box oil level, or not unless the low oil caused damage to the transfer box or caused it to seize, in which case there could be a sudden violent force transfered to the rear diff...

Originally Posted by twr7cx

I don't see how the low oil level in the transfer box would effect the rear diff. The rear diff has it's own oil level. The transfer box should still be transfering power from the gearbox to the diff via the rear tailshaft. I don't believe the method of transfer to the rear diff would change due to the low transfer box oil level, or not unless the low oil caused damage to the transfer box or caused it to seize, in which case there could be a sudden violent force transfered to the rear diff...

I think you may be on to something, when it started happening again it ONLY happened when accelerating and decelerating (so transfer box starts and stops?) it was very violent and got progressively worse. In any case, once I get my rotoflex and bushing I will (hopefully) let you know the good news.

ok so here are some pictures. I have recently read that having flakes and chunks in the oil is not a good thing; its a sign that the t-case is going apparently. Can anyone give me some advice, feedback etc. I have changed the oil (what there was of it); changed the rotoflex and bushing of the prop shaft and the diff was changed (for a used one) about 6 weeks ago. When the diff went there was a clunking when accelerating, decelerating and braking. And now it is happening again but not as bad but I fear it is going to happen again. I guess I will have to have a look at getting the t-case replaced but I want to know some things before i start ringing around. Thanks in advance guys.
IMG_0885[1].jpg

gears.jpg

oil.jpg

t case.jpg

Don't jump to conclusions. There is no relation between the Diff & t-case issues. I would not be too alarmed about your T-Case just yet, If it hasn't blown up or overheated whilst running next to no oil it can't be too stuffed. Hard to tell in a photo but unless its brass the gunk looks like old gasket or silicon bits that someone hasn't cleaned out properly. If its brass I'd pull it down !!

If you don't have a hell of a big oil pool on your floor the oil must be going somewhere else - check your Gearbox level too, it may have transferred thru the seals ??

Clean the gunk out, put the bottom back & use a magnetic bung, refill to correct level & check it in 5000klm to see what gives !!

Also check the A frame Ball Joint on top of the Diff housing , if its loose or sloppy that can cause the clunking.

Yeh those chunks are definitely brass . So what exactly does it mean? Does this translate to clunking? Thanks for the help

Edit: A-frame ball joint sturdy and fine
It is leaking as mentioned below which looks like from both the tranny and t-case... Oh joy...
There was a magnetic bung which had even more brass bits than in the picture with the oil pan.

new oil.jpg

oil leak.jpg

old oil leak.jpg

So I have recently added a roverdrive oil sump for the transfer case so the cover is completely spotless, there was A LOT of brass chunks/flakes when I drained it. FYI I am not sure how long it had been unchanged for, probably my fault cause ive had the car for 30,000ks and didnt think of doing it. So on the assumption that it is my t-case does anyone have any suggestions for mechanics who will fit a t-case? I will also get my transmission fluid done as it looks like I have 2 leaks (notice one pic has a clean drop of oil and another has a dirt one). The closer to the hoppers crossing/werribee area the better but willing to drive and pay for quality service and parts. Suggestions for t-case suppliers also appreciated...

So I found a TC overhaul kit from British 4wd in eBay, I'm looking at all options so feel free to comment on this, pros cons etc. I don't know if this is a COMPLETE overhaul as it doesn't look like there are enough components. Damn this D2 is doing my head in, she'd be in trouble if I didn't loved her so much...
http://item.mobileweb.ebay.com.au/vi...424&cmd=VIDESC