Engine/Transmission (1994 - 1998) transfer/case oil leak

[Keith1]

has anyone had a problem with the output shaft leaking oil between the yoke and output shaft,the seal seems fine or at least its not dripping from it and it only seems to do it when the trucks being driven not when its sitting,any help.

 

[mwilson]

Hi kerber,

I am having the same problem with mine. Investigated this yesterday and found extension housing is worn out. I think it only leaks oil when in motion is because transfer case has an internal oil pump. Push up on the slip yoke real hard and see if you don't have some slack in there. You have a high mileage unit like mine and with the huge driveshaft it makes sense that it would wear out. Have ordered all parts and can do repair without removing transfer case. Parts will be in this Weds. and will let you know the outcome. Price for parts is roughly $150. 00. Will post again when I get it back together.

Mike

 

[Keith1]

i took it apart and didn't notice any excessive play from the yoke,just keep me informed on how the parts worked out and if it worked sounds like your on to something thanks

 

[mwilson]

I had to push up on it just right to make it clunk. It was my second attempt before I caught the slack in it. It may be the bearing which is on the forward end of the extension housing. The snap ring for the bearing did not show up today, so must wait another day to tear into it. I ordered the extension housing, seal, bearing, snap ring for bearing and speedo sensor o-ring. If yours is doing the same as mine, your muffler, fuel tank and bottom of cab is covered with ATF, but no visible drips overnight. I changed the seal and fluid in June, filled it at that time, and was down almost a quart last Saturday so pretty sure I'm onto it. Will let you know. Also, filler plug is lower than extension housing so it must pump fluid up there when in motion. I would not think splash lubrication would cut it.

Mike

 

[Keith1]

just another thought i think there is a return at the bottom of the tail shaft from the way it looks in my service manual (small hole in center bottom) that you can see when you take tale shaft off could also be plugged or blocked,what ever it is it sure sounds like the same problem

 

[mwilson]

Kerber

Went to pick up parts tonight and parts guy ordered the bearing housing, not the extension housing like I told him. Makes me mad as I told him to check with his manager to make sure he was ordering the right thing!!! So am headed camping first light, leak and all. Will attempt repair when I get home next Weds. Will check oil drain passage for sure, sounds like a good idea. I will post results when done, provided the right parts come this time!!

Mike :{

 

[Keith1]

i think ive got it its the plug in the back off the yoke had to take ujoint off but it is the plug thats letting the oil by it (looks like a soft plug) i just popped it out and cleaned it real good and used formagasket when i put it back to gether so far so good il let you know if it starts to seep again,i think this may be from a ujoint that was pressed out seems that this started about the same time.

 

[shendren]

kerber, i was under my truck today and saw what appeared to be oil splatter of some sort along the bottom of my fuel tank. i know nothing of transfer cases and the like. any special tools? i've never dropped a drive shaft... . thanks. scott.

 

[Extreme1]

No special tools, I've had mine apart a couple times and reused all the seals, snap rings, etc. The case parts are sealed together with silicone RTV sealant.



I've had a leaky rear output seal for over 4 years. I've tried 2 new seals. When I replaced the trans, I had the dealer reseal the bearing housing to case joint (easier to get when standing it on end). Since then it's leaked. I check the bearing slop next time I'm under there. A blocked vent line would do the same thing.



There is an internal pump that feeds the bearings. These can be run on the highway with almost no lube (in 2 wheel drive) not towing and not wreck anything.



The only tool you might not have is a large transmission snap ring pliers. The kind with the knurled flats instead of the pins. But I think you need those only if you go deeper into it than the tailhousing.

 

[mwilson]

Hi Guys,

I just did the repair on transfer case today (finally) and wanted to let you all know how it went. The bushing inside the extension housing was worn badly, worse on the lower half. The bearing had a little slack as well. Worse part of the whole thing was removing all the old silicone sealant from the transfer case. I also noticed the Mopar replacement bearing was made a lot stronger than the one I took out. I suspect this transfer has been rebuilt before with aftermarket parts. Cost of parts was about 150. 00 and took a couple of hours at my day off pace. I have the part numbers if anybody needs them and have some photocopies of Dodge service book on this and can e-mail them if needed. I will post again next weekend as I put 600 miles a week on the old girl and will know if leak is cured. The clunk and most of the play is gone. I think that output shaft and slip yoke are a little worn but should not bother.

Oh, by the way there is a drain between bearing housing and main case that could plug with use of too much silicone sealer. This drain was mentioned back a ways and I remembered to give it a look.

Mike

 

[shendren]

i guess i'll check the transfer case vent first. i can't locate it. i looked in the service manual but can't find it. it appears mine MAY be leaking from the region just behind the u-joint in front of the transfer case. does this sound right or am i just getting fluid migrating up there? thanks. scott.