Wenzel

I have a 2004 5.4 4x4 SCrew

I was under the truck today replacing a broken gear shift cable and noted that my transfer case was leaking from the tail housing where it connects to the transfer case AND from where the drive shaft enters the tail housing.

I know I need to drop the drive shaft from the rear and slide it out, but I've never been into a transfer case before so I don't know what I need to change or if I'm capable of doing it.

I've looked around on here and haven't found anything exact to my problem. Most appeared as though it was just a leak where the shaft entered the housing.

I learn as I go so any specific detailed advice would be mucho bueno!

Thanks in advance!

donbun68

So it's leaking between transfer case and tranny? As well as tail housing of transfer case?

Wenzel

No. So I know little related to the transfer case. As I state tail housing I'm referring to the cone shaped area on the back side of the transfer case that the rear drive shaft enters into. ATF is dripping out of the small end of the cone where the drive shaft enters as well as where the cone bolts onto the transfer case. Does that make more sense?

donbun68

Oh ok gotcha! There is just a seal on the end of the tail housing where driveshaft inserts. Just remove driveshaft and pop seal out. As far as tail cone leaking at flange that could be more labor intensive. Not exactly sure what you may get into removing tail housing. More than likely it's just a gasket.

donbun68

I know there is some Ford tech guys on here. Hopefully they'll read you thread and give you a more definitive answer.

Wenzel

Thanks. I read something in one post about a bushing or O ring inside. But I'm not sure if it is specific to my problem or not.

Wenzel

So here is a pic of the problem, does this help anyone out?

Do you think maybe the ATF at the large end of the cone is running out of the small end and not actually leaking from the connection?

speeddemon86

Looks like it'd leaking from the slip yoke to me.

Wenzel

Awesome, so how do I fix it? Is it just the rear output seal or is there something inside or a gasket or such? I've never messed with a Transfer Case before, however I replaced my differential seals so I'm hopeful that I can accomplish this on my own.

Thanks!

speeddemon86

I'm pretty sure it's just a seal. I don't think you have to drop the case or anything to replace it but I'm not 100% sure on that