I have the transfer cases out of the truck again to replace all the seals again. This time with gaskets from Marlin Crawler. Turns out my leak was from two sources:
- The bolts on the rear transfer case twin sticks had backed off and allowed oil to escape from between the t-case and the oil slinger plate
- The twin sticks from Trail Gear (came with the truck, don't judge!) are allowing oil to leak past from somewhere (I think the stick pivot points). I'll be replacing with a FROR twin stick assembly.
- The output shaft nut on the rear propellor shaft had loosened and wallowed out the rear seal
None of the case seals were leaking as far as I could tell so that's good. But I opened the cases up anyway to inspect. The silver goop that I had come out before appears to have been from the new 4.7:1 gears carving out a bit more material and everything looks fine. I cleaned out remaining shavings.
I am most of the way through replacing the seals and decided to remove the transmission to transfer case adapter (the one that the transmission shifter comes out of) to replace some of the seals in there (I received those seals from Marlin, too). Now I can't figure out how to get that adapter all the way off of the transmission! It will come off about 1/2" and then go no further. It sounds like something is sticking inside. I've tried hitting it with a rubber mallet and dead blow but to no effect.
Any idea how to get the transmission transfer case adapter off the truck? All nine bolts have been removed. I removed the shifter and undid the linkage to make sure none of that was interfering. The Toyota service manual says to only remove those nine bolts and hit it with a hammer. There has to be something simple I'm missing.
Yes, I have been googling for an answer but with no result yet.
STOP!!! The transmission shifter comes out of the transmission. From the 9 bolts and what you are describing, you are trying to take the transmission apart. This is not good. DO NOT CONTINUE to hit it with a hammer or try to pull it apart. There are more bolts you need to take out, and IIRC some detent balls and springs, and it is better done on the bench.
The transmission has two aluminum cases seperated by a steel plate where the main bearings ride. I'm surprised marlin sent you that seal. At a minimum, they should have sent you two, one for the rear and one for the front, and all of my toyota manuals have always recommended FIPG on that plate, not a paper seal.
At this point, post up a picutre, but I think you are going to have to get the transmission pulled to get that sealed up properly. You can try to reseal with FIPG (which is what the FSM will recommend) on the ground, but its not going to be easy, and I doubt you will be able to clean it out properly. You likely need to pull it apart, clean off the surfaces of the old FIPG, and then apply a new coat. By taking out the bolts and pounding on it, you likely have messed up the seal between the front aluminum case and the front of the steel plate.
As an aside,
There are two types of Transfer case to transmission adapters. The FSM will call the piece you are taking off the "T case to trans adapter", but this is to delineate 2wd and 4wd. Marlin has transfercase to transmisison adapters for non- gear drive transfer cases.
With a 22re, you should have the bellhousing, the transmission, which as I said is three pieces, then the low range part of the transfercase, held on with 6 bolts, then an adapter, then a full transfercase. You do not have a transmission to transfercase adapter such as what Marlin sells.
The 22re came with a W56 trans (in general) and a passenger drop, gear driven RF1A (in general) transfercase. To make a dual case set up on a W56, you only need one adapter, which is why is is cheaper. On my 99, as a counter example, I have an R150 transmission. This has a driver drop, chain drive tcase. The gear drive cases are easily separated into two parts: the low range half, and the 4wd half. The chain drive is not. The chaindrive cases have a different bolt pattern to attach them to the transmission. Therefore, an adapter between the trans and transfercase is needed.
As for gear drive vs chain drive transfercases: on gear drive gears drive the front output shaft, wheras in chain drive a chain does.
