I just bought my 2004 RAM 2500 a couple weeks ago with 160K miles on it. I thought it was a good deal even with a few expected leaks. But this one baffles me. I have tracked my transfer case leak to the fill plug. The plug threads look good. I torqued it the the specs, yet it still dribbles. I suspect it was overfilled. At a significant decline the ATF was level with the bottom of the fill hole. I thought there's no way it could have filled that full without stand the truck on it grille to fill it, especially with it leaking.
Last night I read in other forums that ATF could be transferring from the transmission to the transfer case. Is this possible or likely? I haven't checked the transmission fluid level since I bought it. I will do that tonight.
What would cause enough pressure for the ATF to push past the fill plug?

Thanks,
Cody

 

The tcase has a vent tube to allow for thermal expansion.
If the vent is plugged it could cause the fluid to push past the plug.
I believe there is usually a washer with the plug to help seal it.