Two questions, take your time....

I've got two small problems that are annoying me to death.

First, when I depress the clutch pedal I get a subtle rattling noise. the noise doesn't start until the engine is warmed up and only happens when I depress the clutch all the way in. I can let off about half an inch and it stops. I pulled the tranny, pulled the clutch, everything looks fine. Put it all back together and it's still there.

Second, how in the world do you eliminate the t-case leak at the rear output shaft? I've change the seal, changed the shaft, still leaking.

Any input I could get would be beyond great.

 

First, Welcome from Portland, OR!

On the leak problem, the seal rides on the companion flange or yoke, not he output shaft. Check that carefully for pits in the seal area. It's also common to have the oil leak past the splines on the output shaft that drive the yoke. A little RTV smeared on the splines works wonders for this. Make sure you clean all surfaces with brake cleaner or something similar that will leave no residue. It's also common for the oil to leak past the shims for setting bearing preload. There was a thread on how to solve this. May want to try doing a search on this topic. There were also some part #'s that were helpful for putting TWO output seals on to help eliminate this problem. Also make sure you use some sealer like rtv on the bolt threads that hold the rear output housing on. The oil likes to work past the threads on the bolts and cause a leak also.

On the rattle problem, does it happen when in gear, in neutral only? Might help to pin point the problem with a little more in-depth info.

Nickmil.

 

Re the leak, likely your TC is leaking through the shim pack. Others here have put the shims together with sealant between them (Copper Coat?), though I think that a thick bead of silicon sealer on the outside of the shims makes more sense. I've always done the sealant on a dry, clean transfer case, and let it set before filling with oil.

 

I think I'm misunderstanding you nickmil. The yoke attaches to the E-brake housing which is held on to the shaft by a large nut and the seal is behind the E-brake back plate. If you take the E-brake off, remove the two jam nuts on the shaft, you have the seal. I've had it apart a couple times and don't remember having any shims to replace. It's been a few months since I last tore it apart but, unless I've lost a few marbles, I'm pretty sure of the assembly. Also, I replaced the shaft with an oversized shaft from 4 Wheel Parts and that didn't seem to help at all. I've never heard of TWO seals though. I'll have to look into that one.

The rattle happens whether it's in gear or not. More info is that I replaced the clutch with the center force dual friction and the T/O bearing about a year ago. This noise has just started happening about a month or two ago and I haven't been able to locate it.

Thanks for all your help. It sounds like you guys are really knowledgable and I do appreciate your input.

 

No mechanic here but wouldn't TO bearing be a possible culprit? I know you said you just replaced it but so did I about 3 months ago and mine's rattling now. Difference is Mine rattles when there's no pressure on the clutch pedal and it stops when I put pressure on it.

 

The shim pack that was mentioned is between the main cast iron housing and the little housing that the speedo cable goes into just in front of the yoke and the parking brake, its what preloads the output shaft bearings.

 

I don't suppose you've had an assistant help you in pinpointing the rattle? Zeroing down the location would help.

An idea: loosen the clutch adjusting nut all the way and take the ball off the fork (and any spring on the fork as well). Depress the clutch pedal a few times. That'd at least discriminate between the linkage and inside.

 

You guys are outstanding. Lynn, I really appreciate you turning me on to this site. I've been on the 4wd site for a couple years and actually left awhile ago because we all just argued all the time. This is great. I'm going to go get that seal this weekend, I'll let you all know how it goes.

On the rattle, my Gramdfather (the original owner) has a motto of "drive it till it breaks then you'll know what's wrong" and although I and although I agree with him 99% of the time, I'v egot to go against him on this one. I think I'll get my son out there to listen for it and see if I can't nail down the location.

 

See http://members.cox.net/mrobosson/JeepPics/JP027.jpg for my solution to this. The one on the left is one of the originals, the one on the right is mine. When I set up my shim pack, I got lucky as I found a scrap piece of aluminum the thickness I needed. I made my own 1 piece shim, and cut grooves around the oil passage and bearing hole. My thinking was that the copper spray-a-gasket sealer would fill these grooves making it a better seal. I haven't run my transfer yet, (coming up soon though... ) but I've had gear oil in it for a month now, with nary a drop underneath.

HTH