2nd Gen Non-Engine/Transmission leaking transfer case fluid

[pbell]

I will try to explain this as best as I can so please bear with me!



When I drive down the road everything seems fine until I make a turn at low speeds. I hear a creaking noise coming from under the truck. I search underneath and find that oil is on the underside the floor above the front u-joint on the rear diff. The fluid is red which leads me to think the transfer case seal is leaking... ... . but there is no fluid around the seal area. The fluid is on the u-joint itself. I know when a u-joint goes out it pops but it does not through thin red fluid (auto transmission fluid) every where.



It looks like to me that the shaft that goes over the output shaft of the transfer case has a cap on the end by the u-joint. Would this cap leak and if so has anyone else experienced this problem?



Please help!!!!

 

[Dsul]

I would say the two problems are not related (creak vs. leak). The transfer cases have a tendency to leak out the rear seal. Mine was leaking when I bought it, I put a new seal in and it still leaks . The leak doesn't really bother me all that much, I keep an eye on the fluid level and it's good rust-proofing for the undercarriage. There is supposed to be a vent on the case, if it can't breath it would have a tendency to blow fluid out of the weakest point, the seal. At least my post will bump this back to the top for ya .

 

[skcmcc]

I agree with Dsul,

Most likely two different problems.

The creaking during a turn would probably becoming from a suspension piece, try the sway bars first, may just need a bit of lube.

The second problem is almost certainly the rear seal from the transfer case, I just replaced my second one at 83,000 miles.

Mine seem to last about 40,000 then start weeping.

Good luck!



Steve

 

[GFoley]

Seal

Pbell,



Before you pull the driveshaft and replace the rear output shaft seal try this.



Crawl up under there and clean the tailshaft section off real good, ESPECIALLY on top. Look up there and you will find an oval shaped rubber plug, similar to the one on a brake brum backing plate. Pull this out, apply a bit of sealant to the underside and replace it. This was my problem but I did not find out until AFTER I had a rear output shaft seal replaced. If this doesn't stop the lear, then it may be the seal you think.



My well stocked NAPA machine shop parts house had what I needed for 1/2 of the dealer price.



GLF

 

[Thomas]

The plug is #8 on the attached.

 

[Extreme1]

The slip yoke on the rear driveshaft has a plug pressed in it and that's where it's leaking. Look at the yoke real close, fluid will be on the plug and all over the u-joint. The only way fluid can get there is from the leaking plug, I know, mine leaks.



The fluid loss on mine is so slight that I'm going to wait until the u-joint is bad (you need to remove it to fix the leak) before I do anything. A good hammer blow might do it otherwise I'll have to braze it.

 

[pbell]

I appreciate all the great advice from everyone!



I had a buddy under the truck while I drove the truck forward/reverse with the brake on. (He drives a Chevy so all the necessary safety precautions were taken. ) The axle rotates causing the yoke to slide in and out on the output shaft.



Extreme 1 you are right. The plug looks like it is not evenly set in the yoke. The plug is causing the transfer case leak and the u-joint is going out also.



I believe what caused this was while dove hunting my tires started spinning and the axle started hopping violently. When that happened the yoke maybe went in too far and the output shaft barely hit the plug. I suppose I brought it upon my self for not letting off the throttle when wheel hop occurred! I don't know how I will fix it yet and I am leaving out of town for a week and will not be able to work on it. When I figure out how to fix it I will post the fix.