After working on my 67 for 2 years I finally have it to a point where it's ready for it's first offroad trip. So I drive 3 1/2 hours from the Bay Area to Slickrock everythings working great.I get to the start of slickrock trail stop get out lock the hubs shift into 4 low head down the trail to the camp. Everything seemed fine no problems get out look underneath HOLY SHIT !! my transfer case is pouring out $7.00 a quart synthetic gear oil like an elephant taking a piss. GREAT a whole 200 yards offroad and my truck breaks down. So here's my question why did my transfer case high low seal pop out of its counter bore, this is the seal that the high low shaft that the shift linkage operates slides thru. I made a jury rig fix out of a spare lead battery terminal cable clamp and a hose clamp to hold the seal in so I could make the 3 1/2 hour drive home. Seemed like the oil from the 5 speed transmission was transfering its oil to the transfer case and ovrfilling it , maybe to much oil in the transfer case blew the seal out? All the parts have less than three thousand miles on them, new transmission, new gears and seals in the transfer case. Is there a hole or special seal that needs to be plugged or installed between the Aussie 5spd and the American FJ62 transfer case? Is the synthetic oil to slippery, or softening the seals? I pulled the transfercase this afternoon and I don't see anything obvious wrong, except that one seal that popped out. Any suggestions or experience with this would be welcomed, Thanks

call gary at mudrack, he should be able to help you out.;)

Thanks Orange, if anyone would know he should.

Talked to Gary at Mudrack today and got the information I needed, so I'll pass it along. Yes the hole below the transmission output shaft on the transfercase intermitate case needs to be plugged with a 3/8 N.P.T. pipe plug. Also a little plastic piece needs to be installed, it's called a 5th gear oiler. As far as the 4x transfercase shifter shaft seal popping out , apparently it's not that uncommon if you use any kind of gasket sealer on it when you press it in, like I did. He said the trick is to have the counterbore where the seal press's into and the seal diameter perfectly clean and dry when it's pressed in and their shouldn't be any problems with it popping out. Another bit of useful info he told me was to use Loctite 518 gasket eliminator on both sides of all the transfercase gaskets to insure a leak tight T.C.
Thanks Gary for the tips.