So after I noticed my Tcase leak that seems to have developed I crawled under and sprayed it down with brake cleaner to try to determine where it's coming from.

I have a suspicion that there is a small crack on the left front side of the case directly behind the actuator.

Anybody else ever had this happen or heard of this?

T-case operates perfectly fine, I notice no strange noises or growling, just leaking oil. Leaked about 1 suction gun full in approx 1,000 miles. Shifts in and out of 4wd just fine.

I'm at a loss and a little choked if this is indeed the problem.

Is there an solution to fixing this problem besides total T-Case replacement?

 

Still under warranty? If so take it in.

If not, keep an eye on it... if it continues maybe you can try to seal it up with some JB Weld or some type of epoxy....

 

If the leak is near a bolt on part, it may just be an o-ring or other seal. The only cracked case I have seen personally was cracked when 750+HP hooked up on the drag strip and snapped the front drive shaft yoke at the transfer case.

 

Nope definietly out of warranty by 30,000 miles so no help there

I thought of the JB thing as well. I may try it yet, sort of looks like there is a hairline crack on the left front side behind the actuator, but I could totally get the case off and find that it isn't.

Priced a new case from Dodge today, $2,625 cdn so if I can avoid that I will.

Keep hoping I will find an easy answer.

Maybe pull the skid plate off on sunday and see what I can see. It's definitely leaking pretty good and I don't want to cook the case if it can be salvaged.

 

Aside from the pullers and drag racers (as Nick stated), I've never heard a transfer case cracking from normal use. Of course there are always exceptions. Hope yours is easily repaired.

 

I would drill both ends of the crack to stop it. If it is in a area that you can, I would then grind out the crack and then weld it up or fill it with JB weld. Stopping the crack would be the first priority though.

Tobin

 

Woow there, first make sure you actually have a crack in the case. Those t-case castings left ALOT to desired, they are a very rough casting with lots of rough surfaces that look like cracks but are just casting imperfections. I think the first thing I would do is clean it very well, then take some leak detector spray and spray the area, drive it a short distance and see where the leak is coming from... if you can't get any leak detector spray, then baby powder will work in a pinch...

 

I have heard of the T-case developing a hole in them from a internal part that wears against the casing and causes a hole. My buddy just had this problem, was having transfer case leaking and he took it to the dealer and they found a hole in it and told him that is not an uncommon problem. His truck is an 05 and it seems to be just a third gen thing. Sorry i cant provide you with anymore info, but that is what he told me.

 

Can't say I've honestly heard of leak detector spray?

Who makes that stuff and where do you buy it?

I would definitely try some if it were available.

 

I don't remember who makes the stuff (I get mine for free from a buddy that works at a dealer)... It's just a spray can that basically sprays a white power on the surface.. Dealers use it for mutiple purposes, the majority of the time they use it to find body water leaks...

Just make sure your not leaking from somewhere else before you go drilling holes on a prefectly good x-case. I have seen cases with holes in them but only from the drivechain wearing out and riding against the case, but I have only seen such a thing in VERY high mileage cases (well over 250K)... These cases aren't anything new and nothing has changed to make one year wear out before another... They are a common and very simple chain driven case design that has been used since the 80's in multiple brands of trucks...

 

"I have seen cases with holes in them but only from the drivechain wearing out and riding against the case, but I have only seen such a thing in VERY high mileage cases (well over 250K)..."

I would have thought the same thing, my buddys truck only had 80K miles on it, just doesnt add up to me, idk

 

Get a Magnaflux dye penetrant kit and check for the crack.

Tobin

 

First make sure it is cracked as mentioned above if it is you have a few options:
1) buy a new case half and have a trans shop change the guts over
2) Find a used case with less miles or worn out case and have your parts put in it
3) have it welded by a good weld shop

I have done all of the above and is cheaper than a new Transfer Case.

 

Thanks for the input guys, I had a closer look this morning, topped up the fluid again and checked closer. It's definitely cracked.



there is a sort of a web right below the actuator and there is a crack that runs accrossed it and down under the case.

I drove the truck about 10 miles, then cleaned the area really well with a rag and a can of ether.

Watched it for a bit and sure enough after a few minutes you could see a small bead of tranny fluid accumulate there.

I guess I'm still a little stunned and didn't want to beleive it.

I thought of smearing the rack with RTV or something similar but I figured to stop the leak but figured it would just continue to crack?

Since trhe case still operates fine I'm considering trying to remove the case and have it welded. I don't know if this is a feasible solution or not. I'm worried about the case failing 1,000 miles from home with a load of cattle or something though.

What do you guys think?

 

I would drill the crack or yes, it will continue to crack.

Tobin