Transfer Case

[kingman]

today I came home to find oil on the ground..when I looked underneath it wascoming from my transfer case..I am also hearing a squeaking noise when I turn right especially....does this mean I have a gear box & or transfer case issue?

I had a initial problem with this Transfer case 15 months ago resulting in the replacement of the bearings on the inside and water was also found inside the case..this time around Ive not been through any water yet the transfer case was soaked with oil... Any similar incidence of this issue out there??

[geeves]

Unfortuanatly its a known problem. There is a seal between the gearbox and transfer case that fails. As the gearbox is higher than the transfer case oil runs into the transfer case then sometimes overflows through the breather.
Correct fix is to drop the gearbox split the 2 parts and replace the seal. They should of replaced this seal when they had the whole lot apart as its a known problem but who knows. Worth trying to get a deal from that mechanic. Not a big hope of success though.
Alternate fixes First gearbox oil will need topping up. You can try draining some oil from the transfer case then adding stop leak (chose a good brand) in both transfer case and gearbox. No promises of success but very cheap if it works.
second fitting a extended breather should prevent the overflow hopefully

[teribul]

G'day kingman.
I have had the same problem and as geeves said it is a common issue.
A question for jeeves... would a by pass breather kit as available from Repco for Landcriusers (runs between the two filler plugs) be of any use?

[geeves]

dont know the kit and havent yet had the problem. Its not going to stop the gearbox oil draining into the transfer case but might divert some of the transfer case overflow back to the gearbox although I cant see it being that successful. The reason I suggested the extended breather on the transfer case was to raise the level it oveflows at although this is a less than satisfactory idea as gears are not meant to be fully submerged in oil.
It might be worth a crack.
The most important thing is to make sure the gearbox doesnt run dry. Theres been a few isuzu gearboxes go to the tip after this

[kingman]

Ive been quoted US$500 for this job... I think ill do the stop gap for now and raise that money...How will I know how much Gear oil to put in the gear box tho....Is it possible to put in too much gear oil in the gear box?

[kingman]

Also guys, is there a particular brand of gear oil specified for the isuzu...We believe in Castrol products here in Barbados ;D

[geeves]

For the gearbox use the cheapest engine oil you can lay your hands on. Use a similar sae number to your engine oil. With the warmer temps over there you probably wont run into the problem of hard gear changes when cold that the good engine oils cause.
Fill till it overflows from the filler hole. Too much oil lowers the efficancy but not by much