Broken off transfer case bolt

[ShockDSM]

I noticed one of the bolts going into my transfercase was broken off. Is this a problem or going to be in the future?

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[oneslowwdsm]

Is that a bolt holding the transfer case to the trans or is it a bolt holding the transfer case together?

 

[ShockDSM]

That is a good question. Let me look at the pics I took again and see if I can tell.

 

[2gmitsueclipse]

Perhaps maybe you could post a better picture when you have something other than a lighter?

I would also address the leakage noticeable on the transfer case.

 

[ShockDSM]

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I am addressing that already on another thread. (Rear main most likely) My phone was dying and I couldn't use the flash. Here is the picture after I just changed my battery. Sorry.

 

[oneslowwdsm]

That's a bolt holding the transfer case together. If it hasn't given you issues yet, then you should be OK. I wouldn't go around doing any crazy launches like that though.

 

[ShockDSM]

Cool thanks man! I appreciate the helpful answer. Its just my winter project beater I got for $1500 so no crazy launches for this rusty crusty!

 

[chrysler kid]

In the first picture you posted there looks to be a crack in the case slightly above and to the right of the bolt hole you are referring to. In the second picture you posted the crack can not be seen because of the angle of the picture

 

[ShockDSM]

Im out in the garage right now but don't have my cellphone with me atm.. Let me get under there and check for crack. Thanks for pointing that out dude I never noticed!

 

[donniekak]

Pretty sure that's a dowel and not a broken bolt.

 

[ShockDSM]

No cracks from what I can see, when I look inside the hole where the missing bolt is supposed to be it looks like there is whats left of a broken bolt shaft inside the hole. Now I just looked and there was a drip of oil right next to the big drain bolt on the transfer case, not on the bolt it self but next to it and it looks pretty clean so I assumed it was motor oil because I have recently changed the motor oil but not the xfercase gear oil. Anyways I just took the drip off with my finger and gave it the sniff test and it smells like GEAR OIL! Not real strong like it does straight out of the bottle but I'm pretty sure its gear oil. So maybe the rear main isn't leaking onto the clutch like I was thinking and the xfercase is now leaking. Welp, I guess I need to get this intercooler finished so that I can drive it and see what it does. The clutch just started to feel like it was slipping the other day in and out under high load full throttle in 2nd and 3rd but if I put it in 5th and gave it gas even floored it wouldn't slip so I came to the conclusion with the wet transfercase that the rear main was probably leaking onto the clutch and flywheel and causing it to slip but there was no clutch smell so I don't know.. Any ideals? Looks like transfercase leak might be unrelated to clutch. Oh and also I found an ENORMOUS boost leak from a cracked wastegate vac hose and even bigger one from the intercooler outlet. Thats why the FMIC is going on right now.

 

[2gmitsueclipse]

Honestly, I would be concerned about the possibility of your transfer case leaking. You may want to check the fluid levels of the drivetrain componenents. Imagine how brown your pants will be when your going down the highway at 70mph, and your transfer case locks up..........

Looking at the pics you have supplied, you have fluid from the tail of the transfer case leaking on to the exhaust. I would remove and inspect it. You will also be able to tell if indeed your rear main seal, or input/output seals are leaking on the trans.

 

[Turboterd]

I can take a look at my transfer case and see if I have a bolt or dowel there. That picture is facing towards the rear, correct?

 

[ShockDSM]

Thanks for the responses guys. Brown pants are my least favorite so hopefully I can get this buttoned up! Turboterd the 1st picture is front the rear facing forward thanks!

 

[ThunderChild]

its doesnt look like a crack to me but a casting imperfection. its hard too tell. i agree on the leak tho, the t-case drain plug, rear seal and engines rear main seal all look to be leaking. time for some resealing and redline fluids!

 

[ShockDSM]

Thing is this car is so rusted from sitting for 3 michigan winters in a row with 160,000 miles on it and the motor that every other bolt I've removed have snapped off on things like the front bumper (which is normal) and all the exhaust hangers.. makes me worried about having a rear main seal housing bolt snap off or an oil pan bolt... I just want it to come apart and go back together. Transfercase input and output seals are what you think i should order? I need some help figuring out a few things on this car since it is a 1990 it has some weire quirky things that all the other year 1g's don't have or differ from. if any of you guys are in michigan and want to give a brother a hand I would gladly return the favor AND buy us bomb ass calazones with ranch, maranara, and beer of your choice.

 

[Maes]

Thing is this car is so rusted from sitting for 3 michigan winters in a row with 160,000 miles on it and the motor that every other bolt I've removed have snapped off on things like the front bumper (which is normal) and all the exhaust hangers.. makes me worried about having a rear main seal housing bolt snap off or an oil pan bolt... I just want it to come apart and go back together. Transfercase input and output seals are what you think i should order? I need some help figuring out a few things on this car since it is a 1990 it has some weire quirky things that all the other year 1g's don't have or differ from. if any of you guys are in michigan and want to give a brother a hand I would gladly return the favor AND buy us bomb ass calazones with ranch, maranara, and beer of your choice.

Where in Michigan are you?

 

[ThunderChild]

If I was out that way I'd totally help you, especially if good food and beer is involved. Alas, I'm west coast.

I'd go ahead and do the t-case seals, rear main, possibly center different output seal, and maybe axle seals.

Better to do them while it's apart and things are needing done

 

[twicks69]

That is a dowel location.

Either way, you are better off addressing the mess and figuring out what seals need replacement. Probably a great time to pull things apart, clean them, and service your fluids.

 

[PlanZero]

I've actually had my transfer case lock up on me at 80mph two days after I bought the car due to a leaking drain plug. Pants were yellow not brown. If I wasn't such a retard I would've checked the t case oil when I bought her, but I was an AWD newb. Make sure the t case recall was done on the car or order the revised yoke kit from stm.

 

[ShockDSM]

Thanks for the replies guys. Looks like I have a ton of work ahead of me. Was hoping to drive the car a bit this winter . Maes I am in Dearborn Michigan. Could use a hand for sure. I also have a kevlar timing belt kit with all mitsu pulleys and mitsu tensioner I need to put on the car, got a new waterpump to put on too. I bought the whole kit from STM including the 4g63 timing tools.

 

[ShockDSM]

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Got the fmic core mounted finally. Wrapped the relocated oil cooler lines with vacuum tubing and zip ties to keep them safe. Just working on a bracket for the top middle of the core to the hood latch bar. I am really not looking forward to cutting out the inside edge of the crash bar/ brackets that bolt it down.