Took the truck to the dealer at 45,000 miles to have the transfer case fluid changed. Noticed that the rear bell housing seal was leaking, had dealer repair. Got home, and noticed that transmission fluid was leaking worse than before. Took truck back today (its been a couple of weeks, and leak is much worse, appears to be coming from rear seal, judging from splash pattern on underside of truck). Dealer says that 'something has broken' internal to the transfer case, and I need a substantial repair (>$500 bucks!)

I have perused the discussion forums here and at the Turbo Diesel Register, and nobody talks about transfer case failures - and I am surprised that mine has a problem, considering that I haven't made the power mods that so many have! What could cause a problem this early in the truck's life, and am I going to have more problems with this piece?

Specifics: I run light most of the time, and use the truck about 3000 miles a year to pull an 8000 lb fifth wheel, sometimes in the mountains here of Colorado.

Any ideas would be appreciated. Dealer says that he has contacted Chrysler and they nixed the idea of their footing the bill, but this is the same unit that five months after I took delivery now qualifies for a 7 year/100,000 mile warranty - any tips on getting Chrysler to ante up?