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Drivetrain - 2001 - 2010 Discuss front and rear axle, transfer case, brakes, etc. Transmission questions belong in the appropriate transmission forum below. First through fourth generation...

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Old 04-10-2017, 04:06 AM   #1 (permalink)
DAKOTAKIDDD
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Transfer case leak

Hey guys. Was doing a service today and when I was under the truck having a look around I seen some oil leaking from the transfer case. It was all on the lowest point.
I immediately thought about the pump rub but didn't see any holes and there wasn't much fluid on the case. The skid plate was dry. I have some pics of where the oil was after I wiped it off. Also in one of the pics it looks like a small crack but no fluid leaks consistently from it.

Do I have a bad gasket or something else.

Let me know





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Old 04-10-2017, 04:37 AM   #2 (permalink)
davester
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Maybe the seal between the two case halves is just starting to fail (there is no gasket, just sealant around the edge)? It also could be the drain plug isn't quite tight enough, or was put in too tight, causing that crack you are pointing at?

I would suggest also checking that the fluid is still full, and that you aren't just seeing the last little bit of oil that was in the TC...

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Last edited by davester; 04-10-2017 at 04:38 AM.
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Old 04-10-2017, 08:29 AM   #3 (permalink)
TheBac
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Id lean toward case cracked due to drain plug overtightened.
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Old 04-10-2017, 11:46 AM   #4 (permalink)
lavarock
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Regardless what the cause of the leak is a pump rub kit is in order if it has never been done.

Also a good time to replace the rear case half if it is cracked.

Having run it with low fluid all of the bearings need to be checked and the gears and chain.
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Old 04-10-2017, 05:49 PM   #5 (permalink)
DAKOTAKIDDD
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I checked today and there was a little bit of fluid on the lower case. I checked the level and it was good. Never had to add any. Check the torque of the drain plug and got a little bit. Not much. I hope that's the fix but I doubt it.

I will watch it and start looking into a case and pump rub kit. Any recommendations ?

Thx guys
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Old 04-10-2017, 09:57 PM   #6 (permalink)
willydmax
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I've installed kits from kennedydiesel and merchant automotive and I think the kennedy one is much simpler.
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Old 04-10-2017, 10:30 PM   #7 (permalink)
IGO1320
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Plug was over tightened, boss is cracked.
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Old 04-10-2017, 10:49 PM   #8 (permalink)
mp06011999
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I use teflon tape on my drain plug and I barely tighten the thing - barely, because I didn't want to ever crack the magnesium case. And I have never had the plug leak. I figured I can always tighten it more if it did leak, but can't hardly undo a crack.

Just adding this because you'd be surprised how little tightening that plug needs (w tape on it) to not leak. Same for the fill hole plug.

I have a history of over-tightening things and breaking or stripping. But years ago I FINALLY learned that you can always tighten 'er more if they leak. Don't believe I've stripped or broken a fastener / plug since.
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Old 04-11-2017, 02:09 AM   #9 (permalink)
davester
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I used the stamped metal plate version of the pump rub kit (vs the more expensive version of the pump that is much thicker), and it seems to be working fine in my NP261HD.
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Old 04-20-2017, 12:59 PM   #10 (permalink)
Rickykjr
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When I went to change the transfer case fluid on my new to me 2007 I got about 2 cups of oil out. Filled it up to see what happens. Didnt see any signs of leaks before. I figured the case was shot after running so low on oil, apparently a long time since no signs of leakage. I found a hole rubbed in the sweet spot for case rub. It was right at the full oil level, so it didnt leak sitting still. I was surprised the case isnt noisy, and I decided to try JB Weld for now. I used the quick setting to go over the hole and plug it up. Cleaned some more, and put two more coats of regular JB Weld on it over the next few days. Didnt drive it at all during this time. I made a damn out of foil tape, and filled the whole area between the ribs on the case with JB weld, and spread it out over a large area. That was a month ago, and so far no leaks. I'm keeping a close eye on it, believe me.

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