M/T Transfer Case - Fluid Leak From Trans. to T.case

BULLETIN NUMBER
SB92-05-005

ISSUE DATE
September 24, 1992

GROUP
TRANSMISSION

MUA TRANSMISSION TRANSFER CASE OIL SEALS

AFFECTED VEHICLES

Trooper (KT), Rodeo (UC), Pickup (TF) and Amigo (TC) 4-wheel drive manual transmission models produced before July 1991, equipped with V6 or 2.6L 4ZE1 engine.

SERVICE INFORMATION





Excessive oil in the transfer case and low oil level in the main transmission case indicates that oil is seeping past the transfer case oil seals (Figure 1). If this condition is present, follow the procedures in this Service Bulletin for transmission diagnosis/repair.

As mentioned in the Service Policy and Procedures Manual (section 6.1-7), replace individual components rather than complete assemblies whenever possible.

SERVICE PROCEDURE

1. If there is excessive oil in the transfer case and low oil level in the main transmission case, proceed to Step 2.

2. If necessary, bring the transmission and transfer case oil levels to their proper quantities.

Oil Quantity Specifications:
Transmission Oil - 3.1 quarts (2.95 liters)
Transfer Case Oil - 1.5 quarts (1.45 liters)

3. Road test the vehicle, checking for normal transmission operation.

4. a. If road test reveals symptoms of transmission damage, perform transmission repairs as necessary, following the procedures in the appropriate Workshop Manual. Ensure that new transfer case oil seals are installed during the repair.

NOTE
Use transfer case oil seals listed in the "Parts Information" section of this Service Bulletin.

b. If road test reveals normal transmission operation, remove the transmission assembly from the vehicle and replace the transfer case off seals as described in the appropriate Workshop Manual.

IMPORTANT

The new transfer case oil seals must be installed squarely into the transmission or leakage will occur.

Before reinstalling the transfer case rear cover, install a layer of black electrician's tape around the front output shaft, from the splines to the end of the shaft. This will protect the oil seals from becoming damaged. Remove this tape after reinstalling the transfer case rear cover.





PARTS INFORMATION





FLAT RATE MANUAL UPDATE INFORMATION