times2

My 1991.5 has been leaving it's mark in the driveway lately and It is coming from the T-case. I read the article in the sticky about rebuilding the thing and that seems like a big job. With 113,500 miles I doubt it needs to be rebuilt - isn't there a set of seals or gaskets that I could freshen it up with to solve my problem?

Also my passenger headlight does not always work. Whenever I first turn the lights on it may come on 5 seconds later or I may drive down the road 10 miles before it starts working - but both brights always work. I have not checked the wiring but thought I would ask you guys first if there is a common fix or trick to take care of this.

wannadiesel

I would bet the headlight is a bad ground. The headlight grounds are - of all places - on the top of the core support near the headlights. You'd think they'd have put them somewhere far away or at least hard to access.

BearKiller

If the ground doesn't cure your light, it could very well have a broken filament.

When a filament in a bulb is just broken, but still all there, the bulb will not light by simply turning on the power; but, you can jiggle the bulb, which gets the filament to vibrating, and it will strike an ARC, just like a welder, and burn until the power is turned off.

Once the power is off, the bulb will need a little shake to get going again.

This can come from something as simple as closing a door, or merely climbing into the seat, anything that will cause the filament to vibrate.

The longer it goes, the bigger the gap, requiring a harsher movement to strick the arc.

Does any of this make sense??

bgilbert

Clean the t-case up and determine where it's leaking. Front output and rear output leaks are easy to fix, just need a big socket to fit the nut.

timb

That socket would be a 1 5/16 for the driveline yokes.

bgilbert

AKA the size not always included in 'big' wrench sets and 'big' socket sets . It always jumps from 1 1/4 to 1 3/8, somehow leaving out the 1 5/16. IIRC, I've run into diesel t-cases with different size nuts for the yokes. Could be the auto vs. manual transmission.

G1625S

Mine leaks at the rear output shaft after a rebuild. I'm gonna have to speedie-sleeve the yoke, but nobody has a # for it, so the truck has to be down for yoke removal which, of course, I don't have time for lately