GM Service Manual Online
For 1990-2009 cars only

Cause

Correction

DEFINITION: A visible indication of an external fluid leak from the transfer case.

Review the Symptoms - Transfer Case and perform the necessary inspections.

Rear output shaft seal leaking

    • Replace the rear output shaft seal. Refer to Rear Output Shaft Seal Replacement .
    • Inspect the slip yoke seal surface for wear or pitting. Replace the slip yoke if the surface could cause leakage.
    • Inspect the rear bushing for wear. Replace the bushing if it is worn.

Speed sensor leaking

Replace the O-ring seal on the speed sensor. Refer to Transfer Case Speed Sensor Replacement .

Front output shaft seal leaking

    • Replace the front output shaft seal. Refer to Front Output Shaft Seal Replacement .
    • Inspect the seal bore for damage. Replace the front case half if the seal bore is damaged.

Leaking at the vent tube

    • Inspect for the correct transfer case fluid level. Refer to Transfer Case Fluid Replacement .
    • Inspect the transmission fluid level. Refer to Transmission Fluid Check in Automatic Transmission - 4L60-E or Transmission Fluid Check in Automatic Transmission - 4L80-E.
    • If the transmission fluid level is low, and the transfer case is too high, replace the transfer case front input shaft seal. Refer to Input Shaft Seal Replacement .
    • Inspect the front input shaft seal surface for wear or damage.
    • Reseal the vent tube with the correct sealer. Refer to Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair.

Transfer case to transmission area leak

    • Inspect the front input shaft seal for leaking. Replace the front input shaft seal if it is faulty. Refer to Input Shaft Seal Replacement .
    • Inspect the front output shaft seal surface for wear or damage.
    • Inspect the front case seal bore for damage.
    • Inspect for the input gear bore seal leaking. Replace the input gear bore seal if the seal is leaking. Refer to Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair.
    • Inspect the transmission adapter gasket for leaking. Replace the transmission adapter gasket if faulty. Refer to Transfer Case Adapter Replacement .

Front case half to rear case half seam leak

Disassemble and seal the case halves. Refer to Transfer Case Assemble in Transfer Case - NVG 263-NP1 Unit Repair.