Janset replied:

Ooops. I will try again, Curse that flying fickle finger :-)

My previous Troopie, the old style were famous for pumping the oil uphill from the Transfer case to the Gearbox. I am told that this was because there was only one seal between the 2 cases. So to overcome this problem, the most comon and cheapest method was to fit an interconnecting oil line between the 2 filler plugs and thus no more problem.

I have been told that the problem on the 75 series no longer exists as they (Toyota) now have 2 seals back to back which is supposed to stop this uphill pumping.

My question, does anyone out there have any knowledge in this reguard or, has anyone heard of this still happening?

Regards

Member - Peter replied:

I've had two 75's and yes it does happen and in the early ones (pre1990) it was due to the one way seal between transfer and gearbox and yes fitting a tube between the filler plugs was an option. The eventual fix was to fit a seal from an automatic cruiser as they had two lips to stop the atf mixing with the 90 grade.
In post 1990 vehicles if the oil pumping occurs it is a sign of far greater problems.
toyota fitted a double lip seal and an O ring to the main input shaft on later vehicles to stop the oil transfer BUT this created another problem, the transfer gears are lubricated by the oil climbing up the gear train and seeping into shafts and bearings, but due to the O ring no oil is able to lubricate the splines on the main input gear at the top of the transfer.
In my troopy this resulted in the complete wearing away of the aforementioned splines at 120,000 k's and therefore no drive, on a vehicle that had only private outback touring!
Fortunately it eventually failed at home and not outback. The cost of a new gearbox mainshaft, new transfer input gear, bearing and gasket kits for both gearbox and transfer was considerable, never mind the labour!
To check if your vehicle has the problem, remove the pto cover from the transfer and hold the pto gear (rearmost one) with one hand and then see how much you can move the input gear (front one nearest gearbox) with the other hand, any movement is too much!
I don't think that 80's have the same problem as they have a different gearbox/transfer and the 78/79 series have a gearbox/transfer similar to 100 series.
Peter

Member - Topcat replied:

I've got the oil transfer setup on my gearbox/transfercase (1990 model)& the transmision has done 258,000km without any problems. Change the oil every 25,000km & it is still going strong. Usually the first sign of internal troubles will be the seals on your output drive shafts will start leaking due to oil contamination wearing out the seals.

Have Wheels Will Travel

Bob Y. - Qld replied:

G'day All,

Sold a 75 series last year with transfer hose fitted, and it was a late 90's vehicle. Have had 2 80 series, and work with 3 79 series, but haven't seen this problem so far.

Re Peter's gear problem, towed an opal miner's 75 tojo, out of a creek, where the gear had finally worn out the splines. Was wet as buggery too, but lucky? for them they were in hard country, to work on it. The other cause of this is the large nut on end of main shaft becoming loose. The qiuck fix is to weld the 2 rear gears together, in situ, or buy a made up gear that advertised in 4WD mags.

Good idea about the regular oil changes too. hooroo...

Janset replied:

Thanks guys.

More information the better. I think as a safe guard a bypass hose connection is in order, and of cause the regular and mandatory oil changes.

Regards.

Member - Peter replied:

Something I should have mentioned before about the gearbox and transfer parts. Toyota wanted heaps for the mainshaft and input gear and I was able to get them, a gasket kit and bearing kit from Don Kyatt at Seven Hills, parts looked identical (except for the worn bits ;-)) and cost about a 3rd of genuine. I would get a genuine gasket kit though as the Kyatt gaskets leaked despite putting sealer on them as well.
Peter