I’ve changed the transfer case output shaft seal twice in 10,000 miles and I’m still getting tranny fluid slung on the undersides. Oddly, there was no tranny fluid in the rubber boot, nothing coming out the weep hole. Upon closer inspection it appears the plug in the input shaft (front end yoke) is weak and leaking. It was filthy dirty, and there is no logical reason for it to be wet, any fluid would have been slung off. The input shaft is hollow so there is a “freeze plug” type thing to seal it.

Anyone ever have or heard of a leak in the input shaft of the drive shaft?

Thanks in advance for any input. (Pun intended)

🎄Merry Christmas🎄

 

Yes, it can get punched out if the driveshaft fully compresses.

I have seen people stake or tack-weld that cap back in. Epoxy or rtv silicone to seal it.

 

Thank you for the response. 🎄

I’ve never heard of such a thing, but looking at it why would it not leak eventually.

RTV right over the top of the existing plug? It’s still there, just leaks. Maybe RTV a 2” metal disc over the top for strength? I did that and we’ll see if it works. Didn’t even need to take the drive shaft off.

 

I decided to RTV a 2” aluminum disc over the top of the plug. I drove for 25 miles at 80 mph and not a drop!

 

Nice fix, I'd spray it down with carb cleaner if trying to seal it from the outside, then force it in with a putty knife or plastic scraper....and wait for it to start leaking again.

Sounds like you got it figgered, Merry Christmas!