Haven't posted for a while but can use some help! Noticed a small drip from the T-case a while back but it didn't bother me much at the time. Now it is more than just a drip, the entire skid plate is wet and the best I can see after wiping the excess oil is it appears to be coming from the output of the trans where the T-case bolts on. Is this common or am I looking at something that will have me eating pbj's for a while? It also seems to weep from the seam at the rear of the case but it may just be running down to that point and dripping off. Any ideas on this would be appreciated before I tear the unit out or bust my knuckles, or both! Oh by the way, Not too many trans shops in my area that I trust so I will just have to figure this out myself. Again thanks!!

 

Pulling the transfer case and splitting it open to fix a leak is pretty much a no-brainer.

First time I did mine was 2 hours in and out and resealed. Not much to it, just jump in and go for it. After you get it out, put it on the bench transmission side down and split it open. Pretty hard to screw it up.

If it's just the rear output seal, pop the driveshaft off, pry out the old seal and pop a new one in.


Jeff

 

With just a little bit of effort you can spolit the case without removing. When pulling case half, keep pressure on output shaft so it doesn't fall apart. You can service chain and most internal components by this method. Really should have a factory service manual (FSM) to assist.

 

Do you know if there is a seal or gasket at the trans/T-case connection? that seems to be the culprit!

 

I have the factory service manual but it says nothing about how the output from the trans seals to the transfer case. Gasket or sealer material? I can't believe these two units bolt together without a seal. I guess i'll find out when it comes apart.

 

there sould be a seal for the tranny that the t-case input goes inside. the tcase input is sealed at the front of it's case. my tranny guy told me there sould be no sealer between the two. if you seal them both up you will never know if one or the other it leaking

 

Correct, two seals. One in T-case one in transmission. No sealant between T-case and tranny.
Transfer case isn't that heavy but it's akward. I'd rent a jack if you don't have one already.

 

Problem solved. the trans output shaft seal was bad. Thanks for the help. nothing left to do except wait for the next problem/project to show itself!