'02 Explorer XLT Transfer case leak between halves (help)

[Pyrial]

Hello everyone. This thread has been very helpful to me with an '02 Explorer XLT I recently purchased. It's given me nothing but trouble. Transmission had to be rebuilt.. among other things. Anyways, now, it's leaking from between the two halves of the transfer case. Anyone know how I would go about fixing this? I'm a handy mechanic wannabe so any ideas would help a lot as far as what I should expect, anything I should be extra careful with? Is there a gasket in between the halves or just a silicone type seal?

 

[swetrid]

It is silicone, but real close at the area where the fill and drain plugs are. The case cracks at these spots and give you the same leak.

 

[esclamada]

Check again if it's really a leak in the halves, sometimes it will turn out just a leak in the output shaft oil seal. To confirm clean the whole area with brake cleaner and put a duct tape along the halves and let it run for a day, remove the duct tape and if you find spots along the seam of the halves then you have a leak.

You need to remove the transfer case to reseal the halves.

Here's a thread for the rebuild..

http://www.explorerforum.com/forums//showthread.php?t=182071



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[Pyrial]

Thanks esclamada, I will try that tomorrow. I don't want to rebuild if not necessary. Hopefully it will just be the output seal. Thanks for link.