Leak from plug on transfer case, 03 KJ Sport

[J-Thompson]

Today I cleaned up my transfer case and then changed the fluid (new ATF+4, of course). I took it for a little test drive, and then snapped this pic. You can clearly see a drip of fresh red fluid leaking out from under the output horn. It's definitely not coming from the output seal. Is there a gasket or some other kind of under there that can be replaced?

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This is not what I would call an easy fix
the out put seal is held in place by a snap ring ,IIRC
you will need to drop the rear DS and get a proper seal
and it is not RTV
it is the seal that goes around the yoke or the shaft that comes out of the rear of the t-case
now you do have the np231 so the parts are easy to come by
if it were me I would do an SYE conversion with a Tom Woods rear DS
this would "beef up" things in the rear drive line

 

[resipsa]

Forgive my confusion, but isn't the output seal further up on the horn, around where the DS attaches? I've seen pictures of leaking seals, and the boots are always coated in ATF. I don't have ATF anywhere near the boot.

This is not what I would call an easy fix
the out put seal is held in place by a snap ring ,IIRC
you will need to drop the rear DS and get a proper seal
and it is not RTV
it is the seal that goes around the yoke or the shaft that comes out of the rear of the t-case
now you do have the np231 so the parts are easy to come by
if it were me I would do an SYE conversion with a Tom Woods rear DS
this would "beef up" things in the rear drive line

 

[J-Thompson]

Forgive my confusion, but isn't the output seal further up on the horn, around where the DS attaches? I've seen pictures of leaking seals, and the boots are always coated in ATF. I don't have ATF anywhere near the boot.

yes and no
the "horn" does not contain any fluid
what you are seeing is the fluid leaking out from a bad seal at the "horn"
as well as a bad out put shaft seal ,which is the main problem
you should be able to remove the horn and not loose any fluid

 

[resipsa]

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