Probably a Stupid Transfer case adapter question

[kczak]

Probably a stupid question, I've got an '89 Silverado, 4 speed 4x4. It's got the HD cast iron tranny, and a NP 241C TC. I recently did a clutch replacement on it. That was a cluster, but another story, and after putting it all back together, using a paper seal between the transfercase adapter and the transfer case, it of course developed a leak. So I pulled the TC off and cleaned up all the surfaces, and applied a proper RTV seal. Leaked again.
Dumb question is, when I removed it after the paper seal failed, there was a fair amount of gear oil in there, that was just sitting in the TC adapter, like 3/4 a qrt maybe. That shouldn't be the case, right? So probably a bad output shaft seal from the tranny to the adapter or what?

Thanks,

 

[Nad_Yvalhosert]

No, there is no manual tranny output shaft seal. It's supposed to leak past the output bearing.
The t-case has a seal to keep ATC fluid inside. The tranny uses the o-ring between the trans and the mount, and the gasket between the mount and the t-case as the trannys oil seal.
Clean off all the paper and RTV and inspect for damage or extra gasket material that was missed in the previous attempts

 

[kczak]

Then wouldn't eventually the whole TC adapter fill with gear oil? I just don't recall when doing the original removal for the clutch job this much gear oil coming out, it was maybe a cup, cup and a half. That was after 20ish years or use. Now after about 50 miles of use, it's at least a full quart.

 

[Nad_Yvalhosert]

Then wouldn't eventually the whole TC adapter fill with gear oil? I just don't recall when doing the original removal for the clutch job this much gear oil coming out, it was maybe a cup, cup and a half. That was after 20ish years or use. Now after about 50 miles of use, it's at least a full quart.

No, because it drains back with gravity through the bearing when you stop driving.
There's just gonna be a little residual here and there