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Thread: How in the sh!t could this happen to my driveline?

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    Forum User verified Feedback Score 6 (100%) MADMarc's Avatar
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    How in the sh!t could this happen to my driveline?

    I have 20k miles on the "new" transmission and transfer case. I have ALWAYS kept up on fluid levels due to persistent leaks until recently when it became so bad that I parked the car. I have been doing several different things on the car over the past couple days and took the transfer case off today. WHERE THE HELL DID ALL THE TEETH GO?!

    These are some shots from the output shaft of the transmission that I already have a replacement for, as well as pictures of the transfer case input teeth.

    Transmission:






    Transfer case:



    Oh wait, what's all that crud in the bottom of the tcase?



    MY SPLINES! How the ef did this happen? The transmission (initially) only leaked from what appeared to be the output shaft seal from the transmission. Reason I say that it was the trans is because the fluid trickled down the area where the tcase and trans meet up but the tcase was never low on fluid. Now, again, I always made sure there was fluid in the transmission yet the shafts look dry as hell, not to mention the powder that the splines were all eroded away in...the powder is the same color as the Redline gear oil I put in there.

    Now I'm boned out of more money than I was prepared for...I thought 20k would be find on the magnificent Kormex trans but apparently not. Does anybody have any input? Better yet, does anybody have a good 25 spline tcase they are willing to wave goodbye to?
    60% of the time, my car works every time.

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    Forum User Feedback Score 13 (100%) Austin@STM's Avatar
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    the splines are supposed to be dry. No fluid runs in there, the red is just rusty metal shavings from the shaft wearing out. It is a fairly common problem with OEM, and OEM replacement shafts. The way the car is driven has a lot to do with it to. Do you beat on the car much?

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    Forum User verified Feedback Score 6 (100%) MADMarc's Avatar
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    Good to hear it is supposed to be dry. I have never had the chance to enjoy my car to the fullest because the clutch would slip whenever I would even try to launch it...that's what I get for reusing a clutch I suppose. To be completely honest I baby the hell out of my car because I was always afraid of something like this happening. Is there anything I need to do before putting a new tcase in there w/the new trans to prevent this from happening again? I would totally understand this happening were it after a significant amount of miles but why so soon? AAAAUGH I NEED MORE BEER TO HELP ME THROUGH THIS!

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    You need to grease the splines when installing the transfercase.

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    LW fears my posts Not Verified Feedback Score 1 (100%)
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    ^^^ What they've said. The stock output shaft eventually rusts and grinds down the spool as well. I've seen worse splines than yours actually. Your transmission leaks are a separate issue.

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    Member verified Feedback Score 0 DocWalt's Avatar
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    Amazingly, my transmission leak saved my splines. I've seen way worse splines, but I'd still replace those pieces.
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    Forum User verified Feedback Score 6 (100%) MADMarc's Avatar
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    In such a quick amount of time? Yaaaargh, the upgraded output shaft sounds extremely nice these days. My service manual doesn't say what type of grease to use for that connection. What type do I throw in there and just how liberally?

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    Forum User Not Verified Feedback Score 0 Keyan's Avatar
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    I plan on stuffing as much wheel bearing grease into my splines as I can, when I install my new tcase in a few months

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    LW fears my posts Not Verified Feedback Score 1 (100%)
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    Quote Originally Posted by MADMarc View Post
    In such a quick amount of time? Yaaaargh, the upgraded output shaft sounds extremely nice these days. My service manual doesn't say what type of grease to use for that connection. What type do I throw in there and just how liberally?
    Some people will advocate a thick assembly lube type of grease, but I don't think that's the best thing. I use motorcycle chain lube. It's designed to be waterproof, not fling off at high chain speeds, and you spray it on. From my experience, it really extends the life of the output shaft.

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    Forum User verified Feedback Score 6 (100%) MADMarc's Avatar
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    Thanks for the info. Hell, I might even have some around and not need to go out and buy some. Like Keyan, I WANT to get a buttload of that stuff in there considering what happened but how much is the correct amount?

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