Engine/Transmission (1994 - 1998) Leaky Transfer Case

[radixr]

My transfer case is leaking. The transmission mount is all wet. It appears to be coming from the split between the rear case and the front case. Is removing the rear case possible without removing the entire transfer case? What should be used to seal the two cases together?

 

[snappy]

My 95 transfer case cracked at the speedometer. I did not catch that crack in time and it cost me a trans case. Only warning sign was the speedo acted erratic.

 

[HCannon]

Had the same leak and it turned out to be the housing between the trans. and the transfer case. It is a aluminum and it had a crack in it. I replaced it with another one and about 5k miles it cracked. I found out that you can get a steel one that wont crack so that is what I have now. If that is your problem, I sure recommend looking into putting steel one in.

 

[radixr]

Thanks guys. While I was looking for a crack, I realized the leak is not between the front and rear case halves. It is coming from where the housing on the back of the transmission and the transfer case meet. HCannon, where was your housing cracked?

 

[HCannon]

The first one was cracked toward the front next to the transmission on the lower left side. The second one, one of the ears that the bolt goes broke. It was the one on the top right side. It was hard to find the crack the first time, it wouldnt leak just setting but when you drove it it would leak and with the air blowing it every where you couldnt tell. The second time, when the ear broke it went to leaking big time. It will leak the oil out of the transmission if it is leaking from the housing. I hope all that you need is a little silicone.

 

[snappy]

That leak is from the 5th gear housing. Like Hcannon, BTDT. I replaced it with a cast iron one from Quad 4X4. My housing developed micro fractures.