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Discussion Starter #1
There is an annoying leak coming from the rear of my transfer case that I think I have pinpointed, just wanted to bounce it off you guys. It seems as though the leak is coming from the slip-yoke inside the u-joint area. I'm not really sure how to explain it further, maybe I can get a pic up soon. Now I'm wondering if it's the "pump clip" issue (I haven't seen a leak in the case anywhere) or if it is a result of overfilling the case with fluid.

A little history:

1: Had a leak between the transmission and x-fer case post clutch replacement, so I pulled the x-fer case and replaced the seals as-per GM instructions.
(Many thanks to Dan at Midwest Transmissions for his help on the phone.)

2. Had a very bad leak at the x-fer case rear-seal and pretty much covered everything underneath my truck. I just thought everyone stopped tailgating here in TX until I fixed it. My apologies if you were behind me during that week. Attributed this to pulling the x-fer case twice.

3. After replacing the rear seal I would wipe down everything around the rear of the x-fer case and there would be fluid residue after driving it for awhile. Like 20 miles or more. The fluid level is not going down at all from what I can tell, but there is still build-up after driving it for awhile, especially on the exhaust where it bakes on.

Anyone have a pic of a case-half hole so I can really check closely?

Thanks for your help!

Jay
 

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Pictures courtesy of DP members Windsolar and aquadon


Merchant sells the fix for it. Check out the link to his new site up in the Vendor Forum.
 

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I had a small hole in my transfer case after pulling a trailer to Wyoming and back to Michigan. Problem is internal and GM will not admit there is a problem or fix under warrenty. There is a fix on the market for this problem. Merchant Auto, Holland Michigan (www.dieseltech.com) fixed mine and put on a new transfer case cover and tell me that I should not ever have this problem again. They are a great diesel performance service for GM Duramax trucks and have a good web sight for information on any problems you may have with your Duramax.
 

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Discussion Starter #5
gwtinker said:
I had a small hole in my transfer case after pulling a trailer to Wyoming and back to Michigan. Problem is internal and GM will not admit there is a problem or fix under warrenty. There is a fix on the market for this problem. Merchant Auto, Holland Michigan (www.dieseltech.com) fixed mine and put on a new transfer case cover and tell me that I should not ever have this problem again. They are a great diesel performance service for GM Duramax trucks and have a good web sight for information on any problems you may have with your Duramax.
Hopefully I'll be in the neighborhood in June and he will be able to accommodate. SW Texas is a long way from Holland.
 
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