Technically this is an Ex, but they're similar enough and this particular forum gets some of the most traffic on the site, so if this needs to be moved, my feelings won't be hurt. I'm just looking for visibility and answers.

I've had this 2000 Ex 4x4 Ltd. for 6 months now, my 1st . 270k mi. I was crawling around underneath it to look at tags on my axles since I'm about to regear, and saw this fluid hangin out on the bottom of my transfer case. I wiped it clean, took the truck for a quick spin, came back and saw nothing, so I went on with the other things I needed to do. I went back out just a little bit ago, and it's the same picture all over again; three drops of fluid hanging there. What steps do I need to take from here to diagnose it? And will it hurt anything if I powerwash that crud off the back of my transfer case and start "fresh" with this whole process?

 

well based upon what I saw, That lower plug is to drain the transfer case. So it appears to me that is dripping from there. Use a racket and give it a tug to ensure it is tight. Then wipe and watch.

Might also be a good idea to take the top one out and verify the level.

 

I took a 3/8-drive ratchet with a 10mm hex socket and couldn't get it to budge any. Is there a seal/o-ring/etc. for the plug that can deteriorate or wear out?

I'll pop open the upper one tomorrow and see what it looks like. I didn't want to start opening things today in fear of screwing something up that I couldn't quickly or easily fix.

 

No seal just a plug. Could use some Teflon tape on the threads to seal it.

So you may end up opening the lower plug, letting it drain while you inspect it.

 

Drain fluid and refill make sure not too full.. Put a little liquid Teflon on the plug threads.
Pressure wash the unit and keep an eye on it.
Oh I use synthetic wolfs head atf.
Never seen that hope you dont have a crack.

 

Take a real close look at the 3 o'clock position of the drain plug. Could be a crack hope it's not.

 

Reading that was enough to peel me away from Lethal Weapon 3 and investigate. I hit it with some brake cleaner, a little steel brush, and a few shop towels. It looks like the dark line from before was casting mark or something. Am I crazy?

 

that last pic looks like there are no issues with a crack or other obvious defects.

Still I would suspect something with the sealing of the plug. Now that it is nice and clean, monitor it.

 

I wouldn't be afraid of using some RectumSeal also if you think a plug is leaking. When we used to build up roller boxes (for HDPE pipe liners) there were a gazillion hydraulic fittings and that's all we used with good results.

 

Just a quick update: I drove into town for some quick errands and peeked under the truck after getting back home. Nothing. I bought some.new fluid while I was out, so I'll be doing the fluid change tomorrow or Wednesday.

 

Well isn't that interesting. Keep us posted. I don't think it would quit on its own.