Cause
| Correction
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DEFINITION: A visible indication of an external fluid leak from the transfer case.
Review the
Symptoms - Transfer Case and perform the necessary inspections.
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Drain plug or fill plug leak
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- Inspect for the correct sealer and amount of sealer on the plugs.
- Correctly install the plugs. Refer to
Transfer Case Fluid Replacement.
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Vehicle speed sensor (VSS) leaking
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- Remove the VSS and inspect for the following conditions:
• | Cut or damaged O-ring seal |
• | VSS over tightened causing deformation in the VSS |
- Replace the VSS O-ring seal if faulty. Refer to
Transfer Case Speed Sensor Replacement.
- Replace the VSS if faulty. Refer to
Transfer Case Speed Sensor Replacement.
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Rear output shaft seal leaking
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- Inspect for the following conditions:
• | Overfilled or improper transfer case fluid |
• | Seal improperly installed, worn or damaged |
• | Seal bore damaged or cracked |
• | Rear output shaft bushing for excessive wear |
• | Slip yoke seal surface for wear or pitting |
- Repair or replace the following components if found faulty:
• | Clean or properly route the vent hose. |
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Front output shaft seal leaking
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- Inspect for the following conditions:
• | Overfilled or improper transfer case fluid |
• | Seal improperly installed, worn or damaged |
• | Seal bore damaged or cracked |
- Repair or replace the following components if found faulty:
• | Clean or properly route the vent hose. |
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Leaking at the vent
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• | Transfer case overfilled |
3. | If the transmission fluid level is low, and the transfer case fluid level is too high, replace the transfer case input shaft seal. Refer to
Input Shaft Seal Replacement. |
4. | Inspect for the following conditions: |
• | Seal improperly installed, worn or damaged |
• | Seal bore damaged or cracked |
• | Input shaft seal surface worn, grooved, or damaged |
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Front case half to rear case half seam leak
| Disassemble, and seal the case halves again. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
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Transfer case to adapter leak
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- Inspect for the following conditions:
• | Loose mounting fasteners |
• | Gasket or sealant faulty |
• | The transfer case input shaft seal leaking |
- Repair or replace the following components if found faulty:
• | Inspect for the following conditions: |
- | Seal improperly installed, worn or damaged |
- | Seal bore damaged or cracked |
- | Input shaft seal surface worn, grooved, or damaged |
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Case leaking
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- Inspect for a cracked case or case porosity.
- Replace the faulty case half. Refer to
Transfer Case Disassemble and
Transfer Case Assemble.
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