I have a 99 I bought new with 310,000 miles on it.
The transfer case started leaking and it turns out it is at the seam of the case, and not the seals. I pulled the transfer case out of the truck to make sure it wasn’t a seal. Seals are bone dry. Transfer case is down about a quart.
The question is can I seal the outside of the case without taking it apart? Or can I split the case and reseal it? I can use an aviation grade sealer on the outside that would work better than silicone and is impervious to oil and fuel.
Anyone else have this issue and come up with a fix?

Next question who would you recommend for a remanufactured transfer case? after 300k miles I’m sure it could use an over haul, but it works fine.

Thoughts?

Thanks in advance for any and all advice and recommendations.

Merry Christmas to DTR Mods!