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Transfer Case Leak Diagnosis

Transfer Case Leak Diagnosis


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
1. Inspect for dirty, worn, scored sealing surfaces, or missing drain and/or fill plug sealing washers.

2. Replace if necessary.


Restricted or damaged ventilation hose assembly Replace the ventilation hose assembly, as required.
Leaking at the transfer case left side weep hole
A transmission oil leak at the transfer case weep hole area is caused by the transmission right side drive shaft seal.

A gear oil leak at the transfer case weep hole area is caused by the transfer case input shaft front (inner) seal.


Replace components as required. If the leak is transmission or O-ring related, do not replace the transfer case input shaft seals.
Leaking at the transfer case right side weep hole A transmission or gear oil leak at the transfer case right side weep hole is caused by the input shaft seal located in the rear extension housing. Replace the input shaft seal.
Leaking ATF at the right side axle shaft-to-intermediate shaft bearing location Replace the intermediate shaft seal located in the rear extension housing.
Leaking at rear output shaft area A leak at rear output shaft area is caused by either the rear output shaft seal or the rear output shaft housing O-ring seal. Inspect and replace the rear output shaft seal as required. The O-ring is not serviceable on AAM transfer case.
Leaking at transaxle assembly-to-transfer case interface
A transmission oil leak at the transmission-to-transfer case interface may be caused by the transmission-to-transfer case o-ring seal.

A transmission oil leak at the transfer case weep hole area is caused by the transmission right side drive shaft seal.

A gear oil leak at the transfer case weep hole area is caused by the transfer case input shaft front (inner) seal.



1.
Note

If the leak is transmission or O-ring related, do not replace the transfer case input shaft seals.


Identify the type of oil leak.

2. Replace components as required.


Case half seam leak AAM Disassemble and replace the transfer case-to-rear extension housing O-ring seal.
Leaking through case
Inspect for a cracked case.

Inspect for case porosity.