i dont know if anyone else has had this problem but i founf that my transmission was low on oil but couldnt find a leak. what i did find is that the seal in the transfer case was letting trans fluid transfer into it and then it would leak out the out put seal. the dealership wanted almost $400 to fix this. i purchased the new seal and gasket and repaired it myself in about 3 hours. i removed the rear drive shaft and removed the front drive shaft from the transfercase alone or you can take it out completely if you want. drained transfer case unplugged wiring and one vacuum line. unbloted from trans and removed using trans jack. the bolts are not the easiest to get to. i used a 3/8 ratchet to break them loose then used a stubby 3/8 to get them out because they are around 2 inches long. once down i had to jack up the truck to get it out from under it. i removed the old seal and installed new one cleaned everything up and installed with a new gasket. im not very good at writing this kind of stuff so if you have a question i will try to answer it.

 

Man if only you had some pictures to go along with this but nicely done that sounds like a lot of work for 3 hours!

 

That's some good wrenching. And some good weights you were jack-n around.

 

I had this happen to me too. You are better than me though, I paid the dealer to fix it. It was 280 at my dealer to fix it. The seal failed again in 6 months so they fixed it free, they got a 12 month/12000 mile warranty on work.

 

the one thing i have going for me is that i am a mechanic just not for a dealership. i guess the worst part was getting all the bolts out to seperate the transfercase from the tranny. when i removed the old seal i drill a couple small holes in it and put some svrews in the holes and pulled it out. you dont need a special seal installer it pushes right in no problem and there is a dowel pin so putting the transfercase back in the right spot is easy.

 

I hope a lot of guys read your tip. Been there with some real tough seals to. Thanks

 

I do the same thing in order to remove the rear main seal on my 5.0 and my son's '03 V6 Mustang.

Stewart