I have an output shaft seal leaking which I know how to fix, but it also looks like the gasket is leaking right in the dead center of the transfer case itself. Has anyone ever had this issue ? Is it as simple as pulling the transfer case, unbolting it in the middle , 're silicone , and bolt back together?

 

By your description, I thought I had a similar leak.
I only changed the output shaft seal and the problem went away.
I think it's a matter of the the fluid running down the ridge under the output shaft and then running along the bottom of the case until it dripped.

See if just changing the seal takes care of it.

 

i just got my seal today to do this did you have any problems or tips changing it?

 

Pretty straight forward job. It went fairly easy.
I cut off the boot portion of the seal so I could get a better look at what and where the seal puller was in contact with.

I put a bit of grease on the inside of the seal ring (the area that contacts the drive shaft yoke. And also a light coating of trans fluid on the outer portion of the seal to help with installation.

Also, be sure that the little hole in the boot is at the bottom when the seal is installed.

 

Ill try that first. I gotta do my pinion seal in the rear too. Have you had to change this also? A few old schoolers I have spoke with said there is some sort of crush plate or something in there I have to torque just right or it'll destroy the rear end.

 

I've never done a pinion seal so I can't help you there. You might try Youtube for some pointers tho'.

 

You should replace the pinion nut. Then only tighten the nut enough to have 15 INCH LBS to turn the pinion with no load.

You have to put some serious torque to crush that sleeve.

I don't think Ford uses the crush sleeves in the 9.75. I know they don't use them in the 8.8 as they set the pinion depth using shims