Noticed a problem w/ my '95 (E4OD, & E-Shift BW1356) recently. Appears ATF is leaking from the tranny, into the TC. Tranny fluid gets low, & TC gets overfull - then starts leaking.

Figure someone here must have run into this before, so thought I'd ask. Is this common - or even possible? If so, what's the fix?

Shifts & runs fine. No "unusual" noises...

Your thoughts appreciated. Thanks in advance - GCF

 

There is usually a seal in the front of the transfer case , it is bad letting tranny fluid into the Transfer case. should be a 714503 national seal. gasket between the e40d and transfer case should be a 55484 Fel-pro

 

Kind of what I figured. Thanks for the tip, & the PN's.

The trans was rebuilt about 70K back. I'm thinking there is an output shaft (on the trans - where the transfer case bolts up) that must have a seal on it, as well. Is this the case? If so, maybe it got neglected during the rebuild...

 

There is usually not a seal on the transmission. Just the shaft sticking out of the back of tranny going through the adapter to transfer case. BUT I have not had a E40D and transfer case apart.

 

This is generally what the back of the transmission looks like:



This is the front of the transfer case:



There's a seal that's pressed in around the input on the transfer case side:




If you have fluid leaking from the transmission and into the transfer case, both the seal on the back of the transmission and the seal on the front of the transfer case would have to be bad. That seems a bit unlikely to me.
They'd have to almost be outright missing for it to be transferring that much fluid. If they were bad, you might get a few drips or something, but a full on fluid transfer is pretty severe.

I'd drop the transfer case and take a look. It's not too hard. Disconnect the drive shaft and any shifter linkage (if it's not automatic). Undo the six bolts and lower it down. If it has fluid, it'll be a bit heavy, so be careful. Probably around 80 to 100 pounds. Not unmanageable, but a bit awkward while you're under the Bronco. Certainly don't be right under it when you remove it.

Generally, what I do is pull it back far enough so that the alignment peg disengages, but the transmission to transfer case shaft is still connected. That'll allow it to "swing".



Keeps you from having to drop it as far.

 

You can put dye in your trans oil. Drive for a 100 mile and check for dye in your transfer case.

 

You are probably right - a unit to unit transfer is unlikely. Need to get it up on a lift, for a closer look - & fluid change.
BTW, thanks for the "swing down" tech tip, & for providing the great pics.
What's the currently recommended ATF for the BW1356?