Transfer Case Leak Diagnosis

WARNING: This page is about a different car, the 2009 Saturn Vue. However, it is still accessible from the selected car via links, so may be relevant.

Cause	Correction
Drain and fill the unit with new oil with ultraviolet dye J 28431-6: Fluorescent Oil Dye - 6 1-oz before using the J 28428-E: High-Intensity Black Light Kit, when inspecting for leaks.
Drain plug or fill plug leak	Inspect for worn, scored, or missing drain and/or fill plug sealing washers. Replace as required. Refer to Transfer Case Fluid Replacement .
Restricted or damaged ventilation assembly	Replace the ventilation assembly, as required.
Leaking at either of the two weep holes	Left input shaft seal leak will be noticed from weep hole on transaxle side of the power take-off unit (PTU). IDS seal leak will be noticed as transmission fluid from weep hole on half-shaft side of the PTU. Right input shaft seal leak will be noticed as gear oil from weep hole on half-shaft side of the PTU. Transfer case overfilled Inspect for the correct transfer case fluid level. Refer to Transfer Case Fluid Replacement .
Leaking at rear output shaft	Damaged rear output shaft housing O-ring seal Damaged rear output shaft seal
Leaking at transaxle assembly-to-transfer case interface	Replace the O-ring seal. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Case half seam leak	Disassemble and replace transfer case seal. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Leaking through case	Inspect for a cracked case. Inspect for case porosity. Replace the PTU.