Wes96

Hey guys,
i noticed a little puddle of trans fluid coming from my 97 f150's transfer case the past few days. it looks to be coming from my front output seal, but the heat shroud that protects the seal from the exhaust heat is in my way from getting a good look at it.

Ive heard of the seals between the transmission and the transfer case going on these trucks quite often, and leaking the trans fluid into the t-case, but when i took the fill plug out of the t-case it wasn't over full.

im wondering if theres an easy fix to repair that front output seal. i dont want to drop the t-case out if not needed because as most of you probably know its no easy task with the cross member in the way. can you replace the seal with the t-case installed ? or is there a quick and easy fix to fix a leaking seal. i picked up some of that "no leak" trans seal repair, but doesnt seem to do much,may be to far gone by now for that.

jhelrey

You can pull the output seal out and tap in a new one with a bearing race setter.

Austin97

Sorry to tell you but the t-case has gotta come out. Even worse the t-case has to be taken apart in order to get the front output shaft out so you can change the seal.

I hope you're right, I've never done it I was just reading through the procedure. Doesn't make much sense to have to disassemble the t-case just to change a seal.

AFSOCSGT

Every attached transfer case I have ever removed is totally sealed so that the Trans fluid cannot get in there. And a bit of Trans fluid will be in the tail shaft from lubricating the output shaft. Now if it is leaking in between the Trans and the transfer case then the output shaft seal could be leaking inside the tail shaft. I have included a picture showing a removed transfer case so you can see that the fluid can't get in there. Make sure you are checking your transmission fluid level as it might be getting low. To fix it you would have to drop the transfer case, and change the output seal.

AFSOCSGT

Pics.

Wes96

just so you all know, the "output shaft" seal im referring to that is leaking is the one that goes to the front end with the drive shaft attached. as you can see in the picture above.

Austin97

That's the one I am referring to which the Ford procedure says you have to disassemble the transfer case in order to remove the shaft to replace the seal.

Wes96

hey guys,
i figured out what the problem was with my t-case. took a little while for me to get around to it. turns out it wasn't the seal at all. the stock exhaust runs very close to the t-case. when i had some exhaust work done on my truck a few months ago the mechanic must have pushed it back so far to where it was rubbing on the front part of the case. after a few months of rubbing and chafing it has worn a pin size hole in the case and was leaking.

im thinking im going to drill, tap, and bolt the hole with some sealant around the bolt to prevent leaking. or even put a rubber grommet in the hole and epoxy it so it stays.

im wondering how hot the fluid inside the case will get. i moved my exhaust back to where it is suppose to be so its not rubbing anymore and wont cause the out side of the case to get hot. but the heat of the inside fluid may cause the sealant and epoxies to melt if its too hot. any ideas?

Austin97

Make a heat shield out of aluminum or just stick some dynamat to the tcase after you're done plugging it. I'd consider either welding or even jb welding the hole up but whatever you think is best. If it's flat enough to drill and tap that should work. The fluid doesn't get all that hot so epoxy or jb weld would be fine. But like I said if you can weld the aluminum case you'd be way better off.