Forum:
'99 Fourtrak F78 has oil leak inbetween bellhousing and gearbox. Also seems the transfer box bleeds into gearbox causing overfill. Maybe the filler plugs of the two boxes could be joined with a bypass tube, similar to some Landcruisers have - any suggestions please?
Oiled
Oil in the bellhousing could be one of two things, the engine crankshaft oil seal, or the gearbox input shaft oil seal, both require the gearbox to be removed.
For crankshaft oil seal, remove gearbox/transfer case as one unit, remove the clutch and flywheel, the crankshaft oil seal should be visible, prise our the old one, and gently tap in a new one.
For gearbox input shaft, remove gearbox, remove clutch actuating arm and thrust bearing, clean out the bellhousing, four bolts should be visible, remove these and the bellhousing will come off the gearbox. Behind this is the input shaft main bearing and oil seal.
Gear oil seeping between the transfer case and gearbox means splitting the two, this may be awkward unless you have a manual or know what you are doing. These have a bearing and oil seal between the two, as well as a gasket, both the bearing oil seal and gasket will need replacing.
Oiled
Thanks for responding - here in RSA these cars and spares are few and far between. Could it be the damage initially due to faulty/blocked breathers on the gearbox and TB? The TB has a breather bolt on top with no hose connected. The gearbox has a breather union T with one hose leading towards the engine bay and no tube on the other side of the T.
My manual is unclear on setup wrt breathers. Also shows a transmission case gasket which on my vehicle has been replaced by just some patches of sealant.
Now to find a proper mech....
Regards