Jeep Wrangler TJ Full Electric Conversions

Leaking ATF after SYE install

hear

hear

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Did my SYE install about 2ish months ago, everything was great. I've had it parked for about 2 weeks in the garage while on vacation, and came back to find a pretty decent puddle of ATF under it and dripping from the skid plate. It has probably been leaking all this time but was being caught by the skid plate and there was finally enough to over flow it, although I need to remove the skid to see exactly what it happening up there and attempt to trace the leak.

My question is around seals & gaskets, as in, I didn't replace any. Should I have?? I don't recall there being any gaskets involved other than the RTV to mound the case halves and the output housing. I remember seeing a seal on the transmission output before I mated them back up, and maybe a gasket? None of the instructions or videos ever mentioned messing with that stuff, so I didn't either.
 
Thoroughly clean the transfercase of ATF, drive the Jeep for a day or so and then reinspect.
The problem could be the RTV that seals the case halves, the output shaft seal (a new one should have been installed) or a leak between the yoke splines and the yoke. A dab of RTV should be applied to the output shaft splines prior to assembly.
Determine which of these is the problem and reseal.
 
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CharlesHS said:
Thoroughly clean the transfercase of ATF, drive the Jeep for a day or so and then reinspect.
The problem could be the RTV that seals the case halves, the output shaft seal (a new one should have been installed) or a leak between the yoke splines and the yoke. A dab of RTV should be applied to the output shaft splines prior to assembly.
Determine which of these is the problem and reseal.
Click to expand...
Yeps you need to replace that output shaft seal when doing the reinstall.
 
This was the seal part number for my 05. It was hard for the parts guy to look up for some reason.

4446487

edit - this is only for the input shaft I believe which was leaking on mine.
 
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finally was able to get underneath it this afternoon & drop the skid pate to inspect.

  • As I suspected, there is a ton of ATF pooled up in the skid, confined to the front drivers side quadrant-— which may just be the lowest point on the skid and the source is elsewhere.
  • No sign of ATF anywhere on the t-case, including speedo gear fitting, shifter linkage, breather tube, rtv/mating surfaces, front/rear yokes & seals...
  • Checking the fluid level in the t-case, it immediately started to run out when I loosened the fill plug.
  • The transmission pan, and especially the rear edge appears to have some fluid mess on it. That section is above the skid, which seems relevant as I sleuth this out.
I don't believe the t-case & trans (I have the 32RH) share fluid, so if the case is full then it must be from the transmission. I would check the level, but I don't want to start the car & run through the gears with the crossmember out & everything supported by a jack, and it's probably a good time to change the filter, fluid, and the pan looks like it is every bit of 24 years old so maybe I'll replace it too.

So, any tips on where I can find a new pan, preferably with a drain plug? Seems like the only ones I can find are deep pans which seems like it would only reduce my clearance, and capacity isn't really my problem. And ideally not expensive.
 
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The t case and transmission DO NOT share the same ATF...
You will need to wipe down the ATF on the transmission to assist in determining the leaks location.
The leak could be the transmission output shaft seal or the pan gasket.
The Summit Racing link below is for a 32RH pan with a drain plug, but I am sure there are other vendors and manufacturers that are available.

https://www.summitracing.com/search...rain-plug-included/yes/transmission-type/32rh
 
Thanks, that's for a deep pan, which I don't think I need and also would it even clear the skid? And it's $160, why does a stamped part cost so much??

I wiped it all down last night and checked just now...the bolts right around the area above the puddle have atf on them now, so the pan is definitely a/the source. I have new fluid & gasket coming, can't bring myself to spend $160 on a new pan just yet. Hopefully the lube locker gasket will be enough.

PS Mopar ATF+4 is way cheaper on Amazon than anywhere else I've found.
 
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replacing the pan is only possible if you can get the old pan out. The final bolt is directly behind the exhaust hanger. I was able to loosen the bolt in the hopes it would clear, but alas that ain’t happening. Removing the trans mount isn’t going to help (I don’t think) because there isn’t really any play in the exhaust/cat at that spot, even pulling on it hard. I think my best option is to attempt to bend it out of the way, since it doesn’t seem like it was welded on square to begin with. Or I cut it off & attempt to re-weld it (I suck at welding).
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The answer is to heat that bar up till its red, then bang on it with a BFH precisely 5 times. Not 6. Not 4 unless you plan on hitting it once more. 7 is right out.

One lube locker later and I appear to have stopped my leak. My heart did sink a little this morning when I went to check it and found more liquid in the same spot on the skid. Till I realized it stormed overnight and it was only water up there. How water from a rainstorm got onto my skid is an entirely different question. ❓
 
Well I still have a leak. I haven’t driven it, but I have run it for about 20 minutes while checking the level after replacing the gasket with a line locker and filling it back up.

the leak isn’t super bad, but it’s definitely more than a drip after 48 hrs. I haven’t re-dropped the skid yet, but I can see some red fluid on the rear lip of the transmission pan. So my pan could be bent a little there, or it could be from behind/above that, which I guess would be in the transmission/t-case mating area.



none of the videos I watched on doing the SYE mentioned replacing any seals or gaskets, but you guys said I needed to...forgive my ignorance, but exactly which seal or seals needed to be replaced? As in can you describe the location? Ie “rear of t-case by the rear drive shaft yoke” or whatever.

thanks

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85700322-64EB-4C0C-BBDB-9EA40B1FAFA0.webp
 
Mine required a rubber star washer that was installed under the nut holding the rear output yoke on. I posted a pic and part number above.

I have a JB Conversions SS Sye and the instructions said it didn’t need the washer but mine leaked without it so I installed one.
 
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This would have been a good seal to replace anyway when the TC was off. But if aint broke dont fix. now she broke
 
hear said:
Well I still have a leak. I haven’t driven it, but I have run it for about 20 minutes while checking the level after replacing the gasket with a line locker and filling it back up.

the leak isn’t super bad, but it’s definitely more than a drip after 48 hrs. I haven’t re-dropped the skid yet, but I can see some red fluid on the rear lip of the transmission pan. So my pan could be bent a little there, or it could be from behind/above that, which I guess would be in the transmission/t-case mating area.



none of the videos I watched on doing the SYE mentioned replacing any seals or gaskets, but you guys said I needed to...forgive my ignorance, but exactly which seal or seals needed to be replaced? As in can you describe the location? Ie “rear of t-case by the rear drive shaft yoke” or whatever.

thanks

View attachment 265272
View attachment 265273
Click to expand...
There are two output shaft outer seals. One where the front shaft exits the TCase, and one where the rear shaft exits the TCase. If all the fluid is forward of the TCase and on the drivers side, all over that side of the tranny, you may consider the front driveshaft outer seal.
 
JMT said:
There are two output shaft outer seals. One where the front shaft exits the TCase, and one where the rear shaft exits the TCase. If all the fluid is forward of the TCase and on the drivers side, all over that side of the tranny, you may consider the front driveshaft outer seal.
Click to expand...
But only if your fluid is low on the TC. so regardless your removing the TC for a TC seal or a Tranny seal. I vote tranny seal is ya problem. but also try not to reuse seals when possible to avoid leaks.
 
Jeffseven777 said:
But only if your fluid is low on the TC. so regardless your removing the TC for a TC seal or a Tranny seal. I vote tranny seal is ya problem. but also try not to reuse seals when possible to avoid leaks.
Click to expand...
Of course. I’m not voting for any location, just making a suggestion on where to look. Fluid level check is always the first thing you do. Guess we should spell everything out. OP seems like he doesn’t know where to look, and fluid on the tranny does not mean it is leaking from the tranny, though it may be.
 
For sure. Never know especially with fluids.
Any seal always replace its good practice cause when they do wear out its a pain to get back to them.

O and for that Bolt you couldnt reach cause of the hanger. you could have removed your tranny mount and ratchet strapped the exhaust out the way. But idk if that would work cause i only have owned MANuals
 

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