Hello from Austria!

Matt Colie

Well-known member
Oct 25, 2019
1,549
456
83
South East Michigan near DTW
Matt,
That corrosion to the end bell may well have been caused by the failure of the exhaust donut.
One several occasions, I got a local muffler shop to put a bell on a short piece of right sized pipe and then welded the new bell to the old pipe. This does take some careful planning, but it is faster and less expensive than replacing an exhaust system.
Matt
 

The Revconeer

Member
Sep 12, 2021
117
22
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Yes, thanks for the advice. I usually order just the pipe which I need. 50 to 170 Euros. In one case I ordered a complete exhaust system (Borla) for my Crown Vic which was about 1500 Euros from the US.
Matt
 

Matt Colie

Well-known member
Oct 25, 2019
1,549
456
83
South East Michigan near DTW
Matt,
I do not recognize the gasket that was installed. Virtually all exhaust manifold gaskets have a lot of creep. (Creep is displacement with load and time.) If you possibly can, plan to do several retorques after thermal cycles.
Oh, yes, and if the installer did not end up covered in anti-sieze, he didn't use enough.
Matt - refugee from dyno land and was once a gasket supplier to OE.
 

The Revconeer

Member
Sep 12, 2021
117
22
18
We did a 90 miles test drive on the German Autobahn to check if there are any problems. We met some good friends, had a BBQ and returned late at night.

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What we noticed:
- front turn signal (driver' s side) didn' t work
- rear red fog lamp was dead
- front headlights are still too low
- red transmission fluid loss (Yeeek!)

Please, not another leak! In fall 2021 the Revcon lost all of his transmission fluid in 5 minutes, caused by a broken line near the radiator. This happened directly at my mechanic' s repair shop - after a 600 miles journey. We were lucky.

My mechanic checked the origin of the loss. The fluid came out of the oil dipstick. The weather was very sunny on the day before yesterday. I experienced the same with my 1978 Ford LTD2 in 1997 and with my 1977 Ford LTD Hearse 1999 right after I had bought them and also in the summer time. Both cars were sitting for a long time.

I even called a tow truck for the LTD2 because I thought that the transmission was broken.

The dripping on our Revcon stopped already on our way back at night when the outside temperature was much lower than during the day.

By the way...

How often do I have to change the transmission fluid in the transfer case, which fluid is needed, how can I check the level and how is this oil change done?

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Matt Colie

Well-known member
Oct 25, 2019
1,549
456
83
South East Michigan near DTW
Matt,

I do not know who manufactured the transfer case in your coach, but most that I have worked on (fought with) used a regular gear oil. If what was in there was really thick and stank of sulfur, then that is a hypoid gear oil that probably started out at 80~90wt. There are now good multi-viscosity gear oils and I believe any of those would perform well for your needs.

Matt
 

The Revconeer

Member
Sep 12, 2021
117
22
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It should be the same transfer case like the one in the GMC Motorhomes. My Revcon is equipped with the 1978 Oldsmobile Toronado 403 UPP drive train. How can I check the fluid level and how is the oil change done?

Thanks.
Matt
 

Matt Colie

Well-known member
Oct 25, 2019
1,549
456
83
South East Michigan near DTW
Matt,
There seems to be a small vocabulary problem. The drivetrain where there is a chain to a reversed transmission doesn't call any part a transfer case. That term in used in four or all wheel drive systems where the power can be selected as to where it goes.
I suspect that you are actually trying to identify what here gets called the final drive. In a typical passcar, this would be the rear end, but it isn't in the rear.
The manual calls for GM 1051022 which is a special lubricant for limited slip differentials. What you have is not a limited slip gear set. That be the case, find something like a 75W90 gear oil. Synthetic would be best.
You can check the level by putting a finger in the plug in the cover. If it comes out with lube on it, you are good.
The only way to drain the final drive is to crack the cover loose. This may damage the gasket. So, if you don't have the gaskets on hand or at least material to make new, I suggest that you leave it alone for now. Gear oils are not subjected to the things that damage engine or transmission oils.
Matt - the other
 

The Revconeer

Member
Sep 12, 2021
117
22
18
6 h journey (280 miles) with all of our family members...remember: My military style is only camouflage to scare the bad guys at the rest stops and to prevent road rages. I am not wearing these clothes on a daily basis.

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Two problems:
A) Leaking AC in the front.
B) Strange noises from the front wheels. Could be the wheel bearings.

A) The AC is brand new and was installed 6 weeks ago. Leakage checks never performed in heavy rain, only with a garden hose. I think that my mechanic has probably made an installation mistake...

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Identified water entry point. Provisionally sealed.

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Right now we are "stranded" in the alps trying to fix the problems.

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The Revconeer

Member
Sep 12, 2021
117
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Thanks. It' s right behind of our house. The Revcon is usually parked in Saxony - Germany, but as you know, I am from Austria.

We want to continue our trip to Lower Austria (where my parents live) next week, which is about 290 miles or a 6.5-hour drive.

B) Contacted the former owner today. Front wheel bearings (and drive shafts) new in 2018. Under 3.000 miles since then.

Local mechanic did a test drive - no results. According to his opinion this could be a wheel or a road surface sound, definitely not the wheel bearings.

However, let' s drive and see.
 

The Revconeer

Member
Sep 12, 2021
117
22
18
Ready to rumble...started with my older son this morning.

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275 miles without any problems...and then: Crack! Our Revcon broke down this afternoon while I was cruising 30 mph in the middle of a small village and doesn' t move anymore. Worst case scenario. Has to be transported back to Germany, which is not so easy to organise here in Austria, because of its size.

Only 15 miles away of my destination.

For more details please refer to the "Maintenance, Repairs, and Technical" section.

Thanks.
Matt (sad and helpless)
 

The Revconeer

Member
Sep 12, 2021
117
22
18
Hello Matt,

our ADAC roadside assistance should cover the towing costs. Nobody can help me here, I need my mechanic in Germany for this job. Members of the forum have written that it could be some half-shaft bolts backed out / broke off. This would be the cheapest and easiest way to repair the Revcon or it might be the final drive. In that case I see myself forced to order a new one from Applied GMC in the US (about USD 3.500 and more with shipping and import duties).

Matt from Austria