Transfer case leak repair?

**Renomax2001** · 01-24-2006, 07:20

Jim
Yes I have searched this forum and found the post with the bolts problem at the torquec converter.
If that were the problem in this case, would the leak be somewhere else?
I am taking it in today to get a the problem diagnosed at my service dept. and will report there findings.
Thanks again for your help and education.
Steve

**More Power** · 01-24-2006, 09:07

Mentioning a bolt leak behind the Allison torque converter was only intended to illustrate a problem somewhat similar to yours, and provide information that might solve your transfer case leak problem....

Jim

**Renomax2001** · 01-26-2006, 12:28

In the above photo the spring that came loose or broke off wore a small hole at the indention left and back there you see the wear.

Above and close to the center of the photo you can see the hole about 3 inches above the 3rd bolt and right below the dirtiest part of the case.
Just picked up truck from service dept. with a $1,280 bill.
The problem was a spring came loose from fluid pump inside the transfer case and caused the tention to wear a small hole in the rear half of the transfer case at the drive shaft.

Steve

[ 01-28-2006, 03:49 PM: Message edited by: Renomax2001 ]

mattb5150 · 01-28-2006, 09:04

This is the known problem reported here in the past. I have the same problem fixed with JB Weld by the dealer that is not holding(slowly leaking again). I guess GM expects us to put up with these defects before 100k miles when my 1993 x-case has 250k miles with no problems.

sjd_sd · 01-30-2006, 12:29

my 2002 2500hd had a leak which the dealer claimed came from the seals. They replaced these, and a few days later it started to leak again. This time they said it came from an "upper" seal. In all they charged me $1100. After having it back for a few more days, more leaks. Now they found a "hairline crack" and wanted $1400 for a new housing. I couldn't take it anymore so I pulled the truck out of the dealer and went by the local transmission shop. He found a pin-hole in about 30 seconds which looked like some problem with the way the metal was formed. This mechanic kept it for a day and put some "liquid metal" in the hole. It's been fine ever since and he didn't charge me anything. I would rather drink gear oil than go back to a dealer.

DA BIG ONE · 01-30-2006, 22:51

Perhaps, a new unit maybe a better choice!

http://www.transfercases.com/

**mattb5150** · 03-08-2006, 23:51

Well the t-case started leaking again, drips all over driveway and dirt sticking to the back of the truck and shell. Crawled under and the JB weld was still in place and didn't have a hole bored thru it like I thought it would, so I touched the blob and it moved. Unpeeled it from the case, I guess the fluid forced it off and started leaking again. So I took it back to the dealer for my free fix because it hadn't been 12 months since the last time. Also needed the rear pinion seal replaced for the second time in 99k miles.

Service writer tells me that GM wants them to use a new putty and the truck has to sit over the weekend with a heater nearby (shoplight) to dry due to cold wet weather. We'll see what happens. If this doesn't work I don't think I'll take it back to them again, too much hassle to have the truck gone. Think I'll just keep doing this putty stuff bu do it myself a couple times a year. BTW the service writer told me no one has come back again after having this putty put on their case.

Matt

**SS396** · 03-09-2006, 13:20

Mattb, there is a broken clip inside the TC that is wearing the whole in the case.

The fix is a new rear case half and clip. I would have the dealer do the repair right.

There are trucks out there that are destroying transfer cases because they are loosing fluid through these wear holes. It is more of a problem than people think.

**mattb5150** · 03-10-2006, 00:31

SS I know about the shaft wearing thru the case, GM will not fix this and I'm not going to pay the dealer $1000 to replace the rear case half I can't afford that.

Matt B.

**SS396** · 03-10-2006, 08:30

Matt, sorry about your problems.

Have you checked with a regular repair shop? I just think it will only get worse.

I am fortunate I have mechanical skills so I would fix my own, if you have those skills or know someone who does, that's another option. I don't think it's all that difficult to replace the case half, and a lot cheaper to do it yourself.

Good luck.

**conway** · 03-10-2006, 11:51

Courious. I was under the impression that I could use Transynd in the transfer case. Is that correct?

**DmaxMaverick** · 03-10-2006, 12:23

Originally Posted by conway

Courious. I was under the impression that I could use Transynd in the transfer case. Is that correct?

Transynd is a Dexron III ATF, which is the spec. requirement for the TC. Synthetic ATF is a very good idea for your TC.

**DA BIG ONE** · 03-19-2006, 02:09

http://www.transfercases.com/

Got a new NP246 from them at 1/3 rd dealer price!

**NEW2DMAX** · 08-05-2006, 20:18

Went on a 400 mile trip with no load and when I returned home and parked the truck for a few hours, later found oil on the floor around rear axle -- after further investagation found that it came from the transfer case and blowed back to the rear of the truck. Looks to be coming from the seam on the passenger side of the case. Changed the fluid to see how much fluid I actually lost drained out 1.5 quarts and fill with new 2.0 quarts cleaned up case and checked to see if the bolts were loose bolts seem to be tight. Went for a 20 mile drive and rechecked for leak and there it was still leaking. Done a search on forum and found that other dmax owners said that thier could be a possible flaw in the case anybody know if GM is working to repair?????????????

**Onebigcanuck** · 08-08-2006, 10:54

I meet a chap this summer while having my oil changed, his was leaking and they found a small hole in the case. The dealer said it looked like a casting defect.

**redrider#1** · 08-08-2006, 11:44

IIRC, there is a clip that helps hold the pump in place that can break and let the pump rub on the inside of the transfer case eventually causing a tiny hole in the area you have described. Some people have patched it using JB Weld, some have had a welder patch it, others have bought new/used transfer cases since theirs had no fluid in it by the time they found out. I am not sure of the best fix (if there even is one), but try using the search feature and maybe you can get more info. Sorry for the bad news.....

Take a look here......

http://www.thedieselpageforums.com/t...+TRANSFER+CASE

http://www.thedieselpageforums.com/t...+TRANSFER+CASE

**More Power** · 08-08-2006, 12:51

Another member posted some images in This Thread showing what caused the leaks in his transfer case....

Jim

**beeler** · 08-10-2006, 07:31

Red and MP have the answer. I discovered mine leaking a couple weeks ago during a oil change. New case half should be here today. Looks to me like JB weld or similar would only be a temporary fix. It would wear through soon without that metal tab to protect it.

**NEW2DMAX** · 08-10-2006, 08:03

Well dealer said GM would agree to pay 1/2 the cost to replace the back half of the transfer case -- total cost 750.00 my cost sould be around 325.00 not bad for 3 years out of warrrenty

**redrider#1** · 08-10-2006, 11:58

Well, I am glad you got at least some satisfaction out of the resolution and that your dealer is willing to do at least that much for you.

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