I just completed my dual T-case setup using a couple of 1980's gear driven T-cases. I got no instructions with the adapter plates on how to put them together, but I think I got it right. They both have brand new synthetic 75W90 gear oil, and I slightly over filled them.

I can hardly touch the shifter with my bare hand, and the whole cab gets extremely hot inside after only about 5 miles out on the highway. I cannot touch the T-case housing. I drove it for about 60 miles and it didn't explode, but I didn't like the extreme heat. I know they're supposed to get hot, but this is excessive.

I didn't open the T-case in the back, but the bearings and gears on the front one looked half decent. The one in the back get much hotter than the one in front, and even the tranny shifter feels hotter than what it should be - I guess the heat dissipates forward. I realize the bearings and gears are 25 years old and who knows how long these things sat before I installed them. I'd hate to redo everything again, but if that's what I have to do, then that's what I'll do. Any suggestions? Thanks

Somewhat normal, a good synthetic gear oil can help cut down on the heat, I found a 10-20 degree reduction on mine. But 2 cases is twice the heat of one case and they get hot, more so at highway speeds and when the outside temps are hot, the cases get even hotter.

My Tcase doesn't get very hot at all. and I live down here in FL where it's always around 100F. I'm running Redline lubes for my whole drivetrain. Pull the magnetic drain plugs & see what you have. that can give you a heads up of a problem.

I did not notice my stock single case getting very hot, but when I had a 2nd case installed, that's when I noticed. It is probably the case of getting a certain amount of heat from each case with a fixed amount of air flow to cool them. Shove a second case in there with it's added heat and you get higher temps given about the same amount of air flow to cool them. Just like taking a lamp rated for a 60 watt bulb and sticking a 100W bulb in there. What used to be a warm light is now hot to the touch.

IMHO my "hot cab" / "hot trans/stick" problems are due more to the header and the exhaust pipe rather than the case itself "heating" becuase of friction.....

My exhaust pipe is now only 3/4" from the T-case, which probably doesn't help either. I'll see if I can squeeze a shield in between them. What would be best - aluminum? I'll also have a look at the drain plug. Thanks for the info. So, it sounds as if I might not have to worry too much afterall.