Engine/Transmission (1998.5 - 2002) transfer case leak

[AC]

I have been trying to find the source for my leaky transfer case. I did a search and found that the rubber plug on top of the tail shaft sometimes leaks. I took it off and put some gasket sealant on it and reinstalled it. I also attempted to track down the vent tube to make sure it isn't plugged. I followed the line as best I could and ended up coming out under the air filter. I cleaned that up and then tried to go back and blow air through the other end. No luck. There is one individual line that hooks to the transfer case and then there is a bundle of four others that hook to it. which of these tubes is the vent line? If I end up having to replace the tail shaft bearing is it necessary to drain the case? Any other suggestions?



TIA AC

 

[csevers]

That plug does leak a lot of the times make sure the vent is open mine was pluged and that is why the plug on the tail housing was leaking. I never traced the vent line but I blew it out with a low psi air gun it is tied in with I think the green line to the main transfer case switch. After blowing it out carefully I had no more leaking at all .



Craig

 

[AC]

Thanks Craig,



I will try the green line. I am trying to eliminate the simple stuff before I go fixing something that isn't broken. AC

 

[Loren]

AC,



The four hoses that connect together are the vacuum controls. These hoses select the valves to switch the front axle disconnect. They may do other functions as well.



The single hose is the vent.



When my transfer case was leaking, it was from the rear seal. I had the case off recently, and didn't notice a rubber plug on top, but I may have overlooked it. Mine's a 241HD behind a 6-speed.



The leak appeared to be coming from the case joint between the tailshaft and the main transfer case, but closer inspection revealed that fluid was leaking from the back and running down to drip off the case at that joint.



The rear seal has been redesigned, so maybe Dodge has seen problems with the old style. The one I removed was two pieces. There was a long (about 2") dust cover that extends out the back of the case. Then ahead of that (forward when installed) is the actual seal. I had some trouble getting mine out, but that is because I didn't know how.



I don't know if you MUST drain the fluid, but you should probably change it anyway, so go ahead. Whether you drain it or not, you will get a small amount out the tailshaft when you slide the driveshaft out.



After the driveshaft is removed, examine the seal. It probably extends to the edge of the case. You can either pry on the edge of the seal, or use a block of wood and hammer to collapse the seal into the hole. Deforming the seal will relieve the pressure and allow you to remove it easily. I didn't do either of these.



I punched a hole into the seal with a punch, then screwed a metal screw into the hole, then pryed the seal out with a claw hammer.



It's easy to install the replacement seal with a block of wood and a hammer.



The new seal is one piece, including the dust cover. Be sure to get the small drain hole in the cover at the bottom when you install it. The seal's not cheap. List price from the dealer is about $45.



All of this assumes that the tailshaft seal is your problem, of course. I hope it is, because it's easy to fix.



Good luck.



Loren

 

[AC]

I took the single hose off and blew in it as hard as I could with no effect. I also crawled around for quite awhile and tried to find where the hose is supposed to vent at. I did find what looks to be a vent termination cap behind the air filter. It is clean and looks to be functioning properly. Is there anything wrong with just taking the hose off or putting some holes in it? Then I would be sure the transfer case was venting properly. AC

 

[Whitmore]

I would cut the hose and use it open ended at a high point under the bed of the truck if it were mine,just tie it up with some zip ties, as long as no water was able to get into it I would think you should be fine.



cheers, Kevin

 

[John]

The hose mentioned...

under and behind the OE filter housing is for the front differential.