The internal oil pump has worn through the case - poor design i was told by the transmission shop. Talk to them, they see it all the time. I just replaced mine last fall except i had to rebuild the entire transfer case after it locked up. The half case is only about $300, my rebuild was about $2000 after neglecting the problem.
Locate the fill plug in the center of the transfer case facing the rear. The fill plug is a hex head bolt.
Remove the fill plug and check the fluid level. Insert the short end of an L-shaped Allen wrench into the hole. Spin the Allen wrench slightly and remove it. Some fluid should be present on the tip if the unit is full.
Attach a screw-on hand pump to a bottle of Mopar ATF+4 type 9602 automatic transmission fluid. Insert the other end of the tubing for the hand pump into the fill plug hole on the transfer case.
Pump fluid into the transfer case until the fluid is flush with the bottom of the hole. A small bead of fluid will drip out of the hole when the case is full.
Reinstall the fill plug and torque it to between 15 and 25 foot-pounds of torque. Hand-tightening the plug and turning it 1/2-half turn further with a socket wrench is equivalent to 20 foot-pounds of torque if you do not have a torque wrench available.
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i think that i am having the same problem on my 99 Silverado. Anybody know why or have a solution?
i have a 78 gmc jimmy and my transfer case seems to leak where the front drive shaft connects anyone no wat i should do it only leaks when im driving
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