Engine/Transmission (1998.5 - 2002) 241HD Xfer case leak on top plug???

[TomGolden]

Ok guys, I know this has been at least mentioned before, but I don't recall anyone saying exactly how to correct this problem.



Several months back, my output seal on my Xfer case was leaking. I found a thread on this problem, replaced the seal and all was well. In that thread, I do remember other folks saying that on the 241HD cases, there is a small rubber plug right on top of the output cone which could be the cause. At that time, I felt around on top of the cone, but didn't feel one on mine, so figured mine didn't have this plug.



Ok, so 2 weeks ago while under the truck, I noticed a fair amount of ATF dripping from the Xfer case. I wiped everything clean, and the next weekend, it was dripping again. I verified it wasn't the seal this time. However, I did find that my case does in fact have the rubber plug right on top of the output cone housing. I removed the plug to verify that it isn't split, cracked, etc. and wiped everything off once again.



My question to you all: this plug fits somewhat snugly, but I am rather certain this is the source of my leak. What has anyone else done to stop this?



Thanks

Tom

 

[kess]

Tom Golden,

I had this same problem and had been through the steps you already have done. Upon driving a long distance I could actually get under the truck and remove the rubber plug and I could hear a vacuum being released. This lead me to check the vent for the transfer case. There are a few hoses that lead away from the transfer case but I think the vent is on the top of the case in the front on the drivers side. I followed it to where it ended which was on the fire wall on the drivers side of the block. Not far from the MAP or IAT sensors. I removed the vent head and I could not blow through it with my mouth. I took it to an air compressor and blew back through the head and removed some debris. After this I could blow air through the head and after replacing the head on the vacuum line I have not had one drop of oil leaked.

 

[TomGolden]

Most interesting. Thanks for the tip. Will give it a try tonight.

 

[TradedV-10foraCummins]

Mine was leaking from the plug also. So, I ordered a new one from the dealer. When it came in the part number had been changed to a completely different number, and the plug was a lot thicker and had been reinforced in the middle. It stopped the leaking on mine completely. (Although I did check to make sure the vent line was ok. ) When I get a chance to dig up the receipt, I'll post the part number. I think it only cost two or three bucks.

 

[TomGolden]

Thanks, I'd appreciate the part # when you have the chance to post it.



I crawled under the truck last night, and wasn't able to find where the darn vent line comes out for the Xfer case, but at least since I removed and re-seated that darn rubber plug last weekend, no leaking since then...



Tom