Transfer Case Leak Diagnosis

Cause	Correction
DEFINITION: A visible indication of an external fluid leak from the transfer case. Review the Symptoms - Transfer Case and perform the necessary inspections.
Drain plug or fill plug leak	Inspect for the correct sealer and the correct amount of sealer on the plugs. Install the plugs correctly. Refer to Transfer Case Fluid Replacement .
Vehicle speed sensor (VSS) leaking	Remove the VSS and inspect for the following conditions: Cross threaded Cut or damaged O-ring seal VSS over tightened causing deformation in the VSS Refer to Transfer Case Speed Sensor Replacement . Replace the VSS O-ring seal if it is faulty. Refer to Transfer Case Speed Sensor Replacement . Replace the VSS if it is faulty. Refer to Transfer Case Speed Sensor Replacement .
Rear output shaft seal leaking	Inspect for the following conditions: Overfilled or improper transfer case fluid Blocked vent Seal improperly installed, worn, or damaged Seal bore damaged or cracked Rear output shaft bushing for excessive wear Slip yoke seal surface for wear or pitting Repair or replace the following components if found faulty: Adjust or replace the transfer case fluid. Refer to Transfer Case Fluid Replacement . Clean, or properly route the vent hose. Replace the slip yoke if the surface could cause leakage. Refer to Rear Propeller Shaft Replacement . Replace the rear case half if the bushing is worn. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the rear case half if the seal bore is damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the rear output shaft seal. Refer to Rear Output Shaft Seal Replacement .
Front output shaft seal leaking	Inspect for the following conditions: Overfilled or improper transfer case fluid Blocked vent Seal improperly installed, worn, or damaged Seal bore damaged or cracked Repair or replace the following components if found faulty: Adjust or replace the transfer case fluid. Refer to Transfer Case Fluid Replacement . Clean or properly route the vent hose. Replace the front case half if the seal bore is damaged. Refer to Transfer Case Disassemble and Transfer Case Assemble . Replace the front output shaft seal. Refer to Front Output Shaft Seal Replacement .
Shift shaft detent seal leaking	Remove the encoder motor and inspect for the shift detent seal leaking. Replace the shift shaft detent seal. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Leaking at the vent	Transfer case overfilled Inspect for the correct transfer case fluid level. Refer to Transfer Case Fluid Replacement . Inspect the transmission fluid level. Refer to Transmission Fluid Check . If the transmission fluid level is low, and the transfer case fluid level is too high, replace the transfer case input shaft seal. Refer to Input Shaft Seal Replacement . Inspect for the following conditions: Seal improperly installed, worn, or damaged Seal bore damaged or cracked Input shaft seal surface worn, grooved, or damaged Seal the vent with the correct sealer if it is leaking at the case. Refer to Transfer Case Assemble .
Transfer case to adapter leak	Inspect for the following conditions: Loose mounting fasteners Gasket or sealant faulty The transfer case input shaft seal leaking Repair or replace the following components if found faulty: Replace the transfer case input shaft seal. Refer to Input Shaft Seal Replacement . Inspect for the following conditions: Seal improperly installed, worn, or damaged Seal bore damaged or cracked Input shaft seal surface worn, grooved, or damaged Repair or replace the loose fasteners. Refer to Transfer Case Adapter Replacement . Replace the transfer case gasket or sealer. Refer to Transfer Case Adapter Replacement .
Front case half to rear case half seam leak	Disassemble and seal the case halves again. Refer to Transfer Case Disassemble and Transfer Case Assemble .
Case leaking	Inspect for a cracked case or case porosity. Replace the faulty case half. Refer to Transfer Case Disassemble and Transfer Case Assemble .