Engine/Transmission (1994 - 1998) Fluid Leak at transmission/Transfer Case Connection

[masterstream]

I have a '97 2500 with an auto transmission and 182,000 miles. Aside from the time the dipstick tube worked loose from where it enters the transmission, it has never leaked a single drop of transmission fluid. Last week, I noticed a puddle of fluid where the truck had been sitting on the driveway. Getting under it to address what I thought was a repeat of the loose dipstick tube problem, I found it was leaking from the area where the transmission and transfer case are bolted together. There are two ears machined on the bottom of the transfer case where the bolts are. The one on the driver's side has what I can only describe as a small chip in the aluminum where the ear meets the back of the transmission. After wiping the area clean, you can watch as fluid runs out around this chip. The chip is about 3/16" wide, right on the edge. Is it a chip, or is that little spot machined there? Due to a job change, I rarely drive the truck more that once in 10 days. Is it possible the seal has contracted due to lack of use? I don't find any reference to this problem with a forum search. Anyone heard of this before or have a suggestion on how to stop the leak?

 

[wildmanben]

pull the t-case and replace the output shaft seal. Thats about all you can do.

 

[LBrazdys]

Simple Fix

I park my truck with the chassis sloping downward and park backwards in the driveway. I just keep an eye on the fluid. Simple fix util I can get the seal replaced. Doesnt seem to leak when I drive the truck, however if it sits, it tends to leak.



My truck is all stock with original T-case and trans..... 340,000k miles. Still going strong.