Ok, so I get the idea to check the transfer case fluid level yesterday and backed out the top plug and almost took a hot oil bath. Dumped a quart or so on the floor before I overcame the shock and got the plug back in. I looked thru some old threads and read that the only way this could happen is if the rear seal in the tranny is blown. I've only ever added a pint or so of tranny fluid to it the 18 months I've owned it. I removed the plug again this morning and let it drain till no more came out and got another quart or so. Have not driven it much today but I'm going to keep a close eye on it to see if it's refilling.
Anyhow, is it difficult to change the rear seal?

 

Once you have the transfer case out of the truck it's easy to change the transmission rear seal.

 

The rear trans seal and the transfer case input shaft seal are one in the same. It is a double lipped spring loaded seal that seals from both sides. Remove the transfer case and replace that seal and you're good to go. I've been been contemplating changing mine out. Still looked good last time the trans was out. With 208k miles and no problems, I'm riding it out a bit longer. Maybe the synthetic fluid, I've been running on both sides, has made the difference.

 

Roland type or brand of synthetic fluids you using in diffs, transfer, trans ?

 

I have Mobil 1 Synthetic oils in the power steering, trans, transfer case, and diff.

 

Thanks all, I will put this on my to-do list. It seems that no harm was done since I just returned from a 3200 mile round trip, I will drive it for a couple more weeks and see how fast it refills itself.

 

Hey Roland, would you happen to know a part number for that seal? Would the local parts stores have it or could I order it online somewhere? Thanks a bunch..

 

Rockauto shows it to be a National #710652 and sells for $14.40 The local parts houses, like O'Reilly's, want about twice that price.