When I was under my truck the other day among other things I noticed the transfer case was leaking at the rear output (slip yoke). I replaced the seal in the summer when I had it out so I doubt its that. I noticed there is some play (up and down) in the slip yoke and when I push it up I can see oil seep. Its leaking pretty good so I checked the level and topped it up. When I did I noticed some metal shavings in the oil, I know that some is normal but it seams excessive considering I changed the oil in the summer. Does anyone have any thoughts as to whats going on? Its getting pretty cold so I figure its easier to ask around on here first then crawl under in the snow and try and figure it out.

 

There is a brass style bushing in the tail shaft housing that could be worn out causing your little bit of play a leakage. Mine was so bad it made the truck shake at highway speeds. Or the slip yoke could have a small groove worn into it from the seal riding on it for so long the only way to fix that is to get a repair sleeve or different slip yoke. But i would pull the shaft out and take a look.

 

Thanks for the reply, by pull the shaft out do you mean the slip yoke and take a look? I have heard of a bushing wearing out but I thought that was in the tail shaft of the automatic trans?

 

Your bw1356 t case has the bushing in the tailshaft housing. I had to replace mine when it started chirping. It's easy.. Remove the housing and drive the bushing out and in with a piece of PVC pipe outside diameter 1.96 inch found at the hardware store. That and a block of 2x4 will do the trick. When installing clocking matters due to oil galley, you'll see what I talking about when you drive it out.

I have a very small leak at my rear seal too, even after replacing the seal and bushing.wet with a drop occasionally. Probably due to stub shaft wear.

While your there you may want to consider replacing speedo gears if showing any sign of wear. Minimal bucks and saves taking it down again.

 

It leaks even after doing the bushing?

 

Yes... I changed the bushing because it was worn with chirping with side play. If you changed the seal your most likely cause of the leak is wear on the stub shaft. The bushing itself will only correct side/up down play.

 

The up down, side to side is where it has play so I think that might be it. I might take a look this weekend if I feel up for it. Its gonna be cold! I haven't noticed any chirping though so I am skeptical....