Marlin Crawler "Taco Box" leaking shifter

13973 Views 72 Replies 8 Participants Last post by JailBreakOvelrander, 2 mo ago

rivethead242

Discussion Starter · Feb 1, 2012

Have there been any fixes for this problem? I recently installed a (new out of the "box") taco box in my rig....having the exact same problems as many others have encountered. All my searches keep ending with the same result...PROBLEM NOT SOLVED.

I've considered tapping a breathing into the shifter base, but others have tried that with no success.....

I have ensured I am not overfilled. No oil is leaking out of the fill plug when removed. I can barely touch the oil with my finger through the fill plug. I have put UV dye in it and took a black light to it to make sure I am not overlooking another leak somewhere...nope, it all coming from the shifter. I have the oil baffle (oil slinger) in there, lip facing down.

A recent 50 mile trip with a couple thousand feet gradual elevation gain (for those familiar with the area; Ontario->Hesperia via the I15) and I lost roughly 0.5qt of gear oil. (At least my frame and everything else behind the crawler got a free coat of rust portection.....err dirt magnet

)There is no way this can be considered normal or acceptable.

On normal highway driving (short trips of 10 miles) I'm getting a good amount of oil collecting on the bottom of the case. Enough to drip a silver dollar sized puddle on the ground.

Has anyone found a fix for this? Or do you just deal with oil leaking everywhere and having to top it off on a regular basis? I don't mind a small drip here and there....but with loosing as much as I am, I am afraid of burning up my gears and bearings inside while on those long trips.

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rivethead242

Discussion Starter · #2 · Feb 1, 2012

NorCalPR said:
Are you clocked?

It is possible that the oil is getting slung into the box, and when the pressure rises, it pushes the oil into the breather and into the cavity in front of the crawl box. The breather is on the pass side so the oil slinger just acts as a holder for the oil till the pressure builds.

I had a problem like this with my crawl box. I didn't have an oil slinger so the oil was just getting slinged into the breather. I installed it but because the slinger was collecting all the oil, it still pushed it out.

I drilled a couple more holes on the pass side of the slinger so any oil that got caught, drained back in.

You can also try drilling a new breather on the driver side...

Anywho, sorry for the hijack, but did you have to drain the tranny fluid to install the crawl box? I can't remember if I had to when I did mine. Reason I ask is I am going to change all the fluids before KOH except for the crawl box. I still have to pull that out to do a check up. If I have to drain the oil or add any, I'll wait.

No I am not clocked. (But I do have the 360 clocking adapter if that makes any difference...)

How old is your crawl box? I do not have a breather located on the shifter plate. Apparently the newer style ones have the breather built in to the shifter (as per Brendan at MC). There is "dead space" when I take the knob off the shifter (looks to be more like casting air bubbles rather than a breather though). Are you referring to a breather somewhere else? I am assuming by breather you mean similar to the one on top of the stock tranny shifter. Drilling some drain holes on the oil slinger sounds like an idea….wish I would have come here first. I just RTV’d it and put her back together. Seen a couple guys now post up about putting a breather on with no luck in solving the issue….

No I did not drain the tranny to install the crawl box. The tranny and crawl box do not share oil. However, the crawl box does leak into the dead space between the tranny and crawl box (where the transmission mount is). So be prepared for a mess if you take those 4 bolts out. Apparently this is to allow larger amounts of oil, as well as release some of the pressure build up. I have a 5-speed, not sure if it is any different on an auto or not.

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Wainiha

· #3 · Feb 1, 2012

If I had a problem I would inquire with Wyatt at RST. He seems to know more than most people.

NorcalPR

· #4 · Feb 1, 2012

Perfect. I have an inchworm so the dead space is oil free. I though I remember not touching he tranny oil.

Sucks about the leaks. I battled with leaks left and right on mine. Shifters, adapters, holes, and I was being told by other people "it's normal"

I've been leak free for over 2 years, maybe close to 3? Don't give up, you'll find it.

I do have the sealed shifter which the breather is right on the shifter base. Jim said the stock shifters aren't sealed well. Maybe the vent isn't venting correctly and the extra pressure is puking out the shifter?

rivethead242

Discussion Starter · #5 · Feb 1, 2012

2

I have the IW trans adapter plate as well. However, my final one (I've been through 3 in the last two months...) has all the holes that are not for mounting sealed (tig welded closed). Won the battle of the leaking trans adapter plate. It's a little beyond me how oil is managing to get into the dead space (seals are brand new). But according to Sparky who has the same issue, and Brendan (Freds40) up at MC confirmed that is normal. I don't particularly like that the dead space is filling with oil, seeing as how when I go with FROR tcase mount in the future I will still have to bolts in those holes even without the mount there...but that is a small price to pay for doing upgrades like this.

Looking on IW and TG site (both appear to be the same) I can't tell the difference between the two offered. I haven't gotten on the phone with either one yet...but no where in the part description does it say sealed. Nor do I see a breather on the base.

http://www.inchwormgear.com/store/product_info.php?products_id=1132

http://www.trail-gear.com/single-shifter

Mine is similar to the last pictured one. Not sure if it differs from the MC version (or if they are the exact same product

). But it does have the snap ring with spring. Metal on metal...so not sealed.

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rivethead242

Discussion Starter · #6 · Feb 1, 2012

2

Ok, so it appears as IW no longer has the sealed shifter on there website. However, I do believe this is what I am looking for.

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NorcalPR

· #7 · Feb 1, 2012

Yeah, I think Jim still makes the shifters, you jut have to call him.

Definitely check your breather to make sure it's not plugged. Either oil is getting slung right up the shifter or it's being Puked out when the pressure rises

rivethead242

Discussion Starter · #8 · Feb 1, 2012

Just got off the phone with MC. They are suggesting a short throw shifter, as the base is raised about 1" higher than the one I currently have. Only problem is, it's not sealed so it would be a crap shoot to know if it fix it or not. They are going to call Jim and see if they can track down a sealed shifter for me. Keeping my fingers crossed.

I do not have a breather on crawler. It is metal on metal and acts as the breather/pressure release causing it to puke out of the shifter. It's gotta be because oil is being slung up into it, getting trapped in the space between the oil slinger and shifter plate. When it gets filled up, then starts to puke out the shifter itself. Apparently this is a hit and miss with each crawl box, naturally I have the one that has been nothing but prolems. Keeping my fingers crossed they can hunt down a sealed shifter for me, as I don't want to have to keep refilling on long trips.

Lumpskie

· #9 · Feb 1, 2012

OP: Thanks for a good thread.

I am prepping to go either lefty/dual gear driven cases, or the taco box route. OP do you know if both options have the same issues with puking oil? I'm doing an expo style build and reliability and maintainence free operation are very important to me.

Keep updating this thread, too. I'm eager to hear if the shifter fixes your problems.

rivethead242

Discussion Starter · #10 · Feb 1, 2012

Just got off the phone with IW. They no longer make the sealed shifter, as of a year or so ago. Apparently this issue I am having is so far and few that there wasn't enough profit for them to continue making it.

rivethead242

Discussion Starter · #11 · Feb 1, 2012

MC is currently building me a sealed shifter with a breather. Keeping my fingers crossed this will resolve my issue.

As frustrating as my crawl box installation has been. MC has done a good job at overnighting me missing parts/ faulty parts and making sure I'm a happy customer. Bigmike even went as far to hand deliver the last last trans plate adapter to my door step. Granted all of my issues should have not happened in the first place. I can't complain too much though, its the name of the game when modding our trucks. Hopefully my experience will be well noted so others do not run into the same problems I have had.

NorcalPR

· #12 · Feb 1, 2012

Damn, that sucks. Daves offroad sells a sealed twinstick unit. Maybe they could assemble it so it's only a single stick?

I also didn't use a Toyota oil slinger, I made my own from a piece o sheet metal. The hole that is used for the regular oil slinger has a large hole. The one I cut out only has enough room for the shifter to move fore and aft, an ellipse. It gave less chance for oil to get slung up.

Personally I think not having a breather is a joke. I'd install a breather in the shifter and see what it does. If you need me to make a oil slinger let me know and I can bring it down. I just need some measurements

rivethead242

Discussion Starter · #13 · Feb 1, 2012

I am going to exhaust all options with MC before I start fabricating my own remedies. For all I know at this point they could be modifying a sealed twin stick for a single stick. All Brendan told me when I was on the horn earlier was that he is making me a sealed shifter with breather tapped and ready to go. They haven't left me hanging yet as far as making sure to get me up and running properly. They've already lost a large chunk of their profit with me between 3 trans plates, 7+ packages with overnight shipping fees etc. Until they throw in the towel, I am going to let them continue to do their job that I have already paid for.

I agree, the hole that is there for the oil slinger is larger than it needs to be. Seeing as how the shifter motion is not circular, a "tighter" elliptical would do a better job of keeping the oil down. However, with the amount of oil I have been loosing I don't think any shape of an oil slinger would completely eradicate this leak.

I've got plenty of aluminum sheet laying around from prior projects, and the tools necessary to make one of my own if need be. Only problem I would have would be putting a lip on it since I dont have a press or capabilities of welding aluminum. Thanks for the offer though, it is greatly appreciated!

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rivethead242

Discussion Starter · #14 · Feb 1, 2012

Lumpskie said:
OP: Thanks for a good thread.

I am prepping to go either lefty/dual gear driven cases, or the taco box route. OP do you know if both options have the same issues with puking oil? I'm doing an expo style build and reliability and maintainence free operation are very important to me.

Keep updating this thread, too. I'm eager to hear if the shifter fixes your problems.

I am not sure if both options have the same issues. I only have experience with my application. I have been told though that it's few and far between that this issue happens. Sparky is running the exact same setup I have on the same year taco (04/manual trans/push button tcase) and doesn't have this issue. No idea what could be different between the internals of my unit compared to others, and MC doesn't seem to know either. Guess it just a crap shoot

NorcalPR

· #15 · Feb 1, 2012

rivethead242 said:
I am going to exhaust all options with MC before I start fabricating my own remedies. For all I know at this point they could be modifying a sealed twin stick for a single stick. All Brendan told me when I was on the horn earlier was that he is making me a sealed shifter with breather tapped and ready to go. They haven't left me hanging yet as far as making sure to get me up and running properly. They've already lost a large chunk of their profit with me between 3 trans plates, 7+ packages with overnight shipping fees etc. Until they throw in the towel, I am going to let them continue to do their job that I have already paid for.

I agree, the hole that is there for the oil slinger is larger than it needs to be. Seeing as how the shifter motion is not circular, a "tighter" elliptical would do a better job of keeping the oil down. However, with the amount of oil I have been loosing I don't think any shape of an oil slinger would completely eradicate this leak.

I've got plenty of aluminum sheet laying around from prior projects, and the tools necessary to make one of my own if need be. Only problem I would have would be putting a lip on it since I dont have a press or capabilities of welding aluminum. Thanks for the offer though, it is greatly appreciated!

I agree. I think running a sealed shifter, with a breather behind the oil slinger is going to cure your leak.

Take notice though that my sealed shifter had a breather vent on top of it. I didn't like having it there so I instead ran a barbed fitting. I then put a T to the stock transfer case breather hose. Then those two hoses terminate in the manual tranny bellhousing. I ran a clear tube so I can see if any oil is getting slung into the dead airspace. None so far

As far as making your own oil slinger, no lip is needed. Here's a shot of mine. I made it out of 22gauge sheet metal.

http://ttora.com/forum/showpost.php?p=1552752&postcount=400

Good luck. Don't give up, you'll get it sealed!

rivethead242 said:
I am not sure if both options have the same issues. I only have experience with my application. I have been told though that it's few and far between that this issue happens. Sparky is running the exact same setup I have on the same year taco (04/manual trans/push button tcase) and doesn't have this issue. No idea what could be different between the internals of my unit compared to others, and MC doesn't seem to know either. Guess it just a crap shoot

Is he running the same gears as you? Same oil?

At least Marlin is helping you out. Jim didn't leave me hanging either even though everyone else was saying "Leaks are normal"

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rivethead242

Discussion Starter · #16 · Feb 2, 2012

Oh trust me, I've made it this far. I am not giving up without a fight. Really keeping my fingers crossed a sealed unit with a breather will do the trick. I'll probably do the same thing with running a T in the breather lines. Thanks for the visualization!

No, he is not running the same gears. I have 2.28's, he has 4.7's...But that shouldn't make much of a difference as far as rotational speed in Hi, seeing as how they are both 1:1 in Hi (right?). Not sure on the oil, but I am running Mobil1 75w-90.

NorcalPR

· #17 · Feb 2, 2012

Well, the gears are always spinning, regardless in 1:1 or low range. To be honest when I hear someone say that the front needle bearing can't hold up, I don't get it because it spins when the crawl box is not engaged.

It could be that the stock gearset has the tendency to aim the fluid right to the shifter, while the smaller counter gear of the 4.7 aims to the corner

Who knows. If you need any help I'm sure you could poke around my rig at koh

rivethead242

Discussion Starter · #18 · Feb 2, 2012

Wasn't aware that the gears are always spinning regardless of hi or low range. Good to know. Well then that would make sense seeing as how the 2.28's are spinning at a higher velocity, thus slinging more oil at a faster rate.

And yup, they just took a sealed twin stick and made it into a single stick for me. Talk about a fast turn around...Called em yesterday, they got it built and to my door step the next day. I'll be installing it tonight when I get home from school. This better do the trick!

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NorcalPR

· #19 · Feb 2, 2012

Nice!

I'd recommend a clear tube so you know if oil is getting slung into the tranny area

rivethead242

Discussion Starter · #20 · Feb 2, 2012

I think I may have some 1/4 clear tubing (water lines) that I can use instead of the the black tubing they provided. If not, I'm not going to sweat it too much (at least before KOH). Just need this thing to stop puking!

I'm going to drill a hole in the oil slinger. Any recommendation/reasoning for drilling a drain hole in the baffle directly beneath the breather, or furthest away? I'm thinking directly bellow it will allow for oil to drain first before going up the breather (keeping pressure equal). But directly bellow it might allow for more oil to sling up into the breather itself. What do you think?

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