ORD doubler vent line help

[bp71k5]

So... on the FJ40, it's a known issue that the transmission likes to steal fluid from the transfer case. The solution is a tube from the fill plug of the transmission back to the fill plug of the t'case so the oil can go back. They even make a kit for that.
A similar setup might be something to consider in your case...as a fix...

That's an interesting idea. I'll have to see where I could run a tube like that.

 

[4X4HIGH]

Brian, since your doubler is clocked up 2" how are you filling it? You will need to add extra lube for sure but you might be adding too much and it is foaming them pushing out the vent tube. I would definately run a separate vent line for the 203 and 205 and get rid of that tee. If there was a pressure difference in either of the cases that tee would allow lube to be transfered.

 

[bp71k5]

I'm filling it through the fill hole until it dribbles out. I assumed because it was spitting out the vent that it was plenty full. Maybe I can find a lube with some anti-foaming additives or even thinner oil. Its 75-90 weight or close to that.

 

[4X4HIGH]

If the case is clocked up 2" and you're only filling it through the fill hole then it doesn't have nearly as much lube as it should. It could be getting so hot that it is starting to boil the fluid and the expansion is making it spill out the vent tube. Most people with a 2" up clocked t-case install a 90* fitting into the fill hole and then even a short piece of straight pipe with a cap on it that way the t-case gets filled with enough lube to keep everything happy. You might want to call Stephen at ORD and ask his opinion on this and what he thinks or suggests you should do.

 

[sweetk30]

since we are on the subject.

with 2" up rotation how much lube to fill ?

stock capacity or more ?

and if full reman on both units and had choice what kind of fluid ?

atf as some 205 had this or 75-90 and if gear oil reg or full synthetic ?

 

[4X4HIGH]

since we are on the subject.

with 2" up rotation how much lube to fill ?

stock capacity or more ?

and if full reman on both units and had choice what kind of fluid ?

atf as some 205 had this or 75-90 and if gear oil reg or full synthetic ?

When the t-case is clocked up the fluid level would not be as high as it would be if in the stock orientation so you must add more fluid to the case. (hard to explain but basically you want the amount that the t-case originally called for but because the t-case is clocked it is impossible to get that into the case without modifying the fill plug location higher).

I would run standard 80/90 gear oil assuming it is not a syncro t-case.

 

[nvrenuf]

When I filled mine, also 2" up rotation, the fluid (75-90 gear oil) was at the fill hole with almost a whole qt to go. I pulled the pto cover off and finished filling it to factory spec. I searched the ORD forum 1st and Stephen says the lesser amount is ok but I just wasnt comfortable.

I haven't run mine yet so I don't know it it'll puke.

 

[sweetk30]

no syncro for me. i got 32 output of front.

and figured stock capaciy.

thanks guys.

 

[bp71k5]

Nothing seems to run hot at all from what i can tell. Who knows though. I think I've got a way to run a hose from the vent back to the fill plug with a tee for another vent that runs uphill a good ways into the engine bay. We'll see after some testing on Sat.

 

[bp71k5]

Testing indicates I am a failure at least from 1000 miles of freeway driving. The 205 is now pushing oil forward into the 203 and then that's filling up and pushing oil into the transmission, and now the transmission is leaking from it's vent. Uhhhh.

I think I'm going to have to pull everything apart and try and figure it out when I get back.

 

[nvrenuf]

Any updates?

 

[bp71k5]

Nothing has changed since then. The vent line is no longer leaking from up top, but the leaks still creep up in other places. The thing just seems to leak when it gets hot. I may try switching to synthetic gear oil or try shielding the exhaust to see if that helps.

 

[76zimmer]

Brian do you have a temp gun?

Check some places on the 205 case with that so see how hot it is getting and if it is affected by your exhaust.

Is it possible the case has a crack or a gouged gasket or seal surface allowing seepage?

 

[72blazerguy]

Subscribed. I'm having similar problems, but my 203 is the case puking fluid. No transfer of fluids between the cases (205 is fine), no tranny fluid in the 203, no leaking in the doubler assembly, small seep between the tranny and 203 adapter. Originally ran the 203 vent line to the firewall, what a mess that made. Both the cases seem to be ok temperature wise, definitely the 203 isn't any hotter than the 205. Can't think of a good reason that only one case will puke .

 

[bp71k5]

Since it needs to be running a while to get hot, it'll be a while before I can measure the temp.

I do know that if you have ANY low spots in a line of hose running up to the firewall, that will cause leaking but mine was leaking out of the vent without any hose at all so there some other problem.