2G Transfer Case Leak or Venting?

[ishnish]

Hey guys, so after finally getting my car running, I've probably started it a total of 6-7 times and have driven it three times. The last time I drove it was the longest which was a total of 5 miles Just to get tires changed. This entire time prior to that I never had a single leak, but finally after this drive I think it leaked. Two days after that drive, I moved the car to see this:

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I think it's safe to say it's transfer case fluid because after that, I got underneath the car and snapped another pic:

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My question is, do you guys think it is a leak at the drain bolt or just some venting due to over-filling? Whether it's over filled or not idk because a couple of years ago, I had a guy who actually replaced all the seals for the tranny and transfer case. I also bought the fluids and I'm not sure whether he put in a whole qt of the Redline heavy shock proof or just half.

Reason I wanna know is I rather save the $30 if I can instead of buying what's needed and finding out that it wasn't actually leaking. Any input?

Thank you

 

[Mello]

Too me it looks like the drain plug is leaking. Did you use a new copper crush washer last time you had the drain plug out? I would remove the fill plug & see if any fluid comes out. This would let you know if the transfer case is overfilled.

 

[ishnish]

Thank you Mello, that is exactly what I'm going to do. It does look like the crush washer is used. Like I said, I didn't do the job so I don't know. I'd It probably reused. Found out he doesn't have the greatest rep . But you live and you learn. I sure as heck didn't have the tools , time, or know-how to touch the tranny. I'm about to go outside, Jack the car up, remove the fill plug, and lower it to level out the car and see what happens. Probably be a good idea to brake clean around the area first or check if the leak is coming from above the bolt .

 

[techboy]

It's hard to tell in the pic ... is the drain plug wet? If so, safe bet it's the crush washer on the drain plug. You can probably get a new one from Extreme PSI or just measure the dia with dial calipers and get one a local parts store. Pulling the plug though will mean you'll have to refill the case with fluid, but at least you'll have peace of mind about how much fluid is in there.

 

[miliman13]

What i have done; empty fluid measure displacement.
Calculate loss make an educated guess.

Honestly all i have done is change washer and rear seal. I do recommend using a dye to verify.

 

[PlanZero]

Check your fluid!! I had my tcase lock up on me at 80mph the day after I bought the car because the previous owner's mechanic didn't tighten the drain plug. There were several oil leaks on the car and it was my first time dealing with gear oil so I didn't realize it was leaking. The two hour trip home must've drained it completely. I had to replace the tcase. That was my intro to AWD.

The tcase recall was for a leaky yoke so judging from the looks you're not leaking from there. Check the drain and fill plugs clean it up and keep an eye on it. You do not want that to lock up due to low gear oil. When you remove the fill plug oil should seep out slowly. That's how you know it's full.

 

[ishnish]

Thank you guys all for the replies.

Yesterday I removed the fill plug and the car's front was raised and it was still draining from the fill plug! So definitely over-filled. Then I removed the drain plug and it felt pretty dang loose be wise I was able to take it off pretty easily in comparison to the fill plug which took quite a bit of elbow grease.

Anyway, the fluid coming out was brand new which sucked but whatever. I went to a local shop and got some heavy shockproof and then got brand new copper crush washers, one was a 16.4mm since that was the closest to 16mm for the fill plug, and the other was an 18mm which was closest to the 18.2mm for the drain plug.

I filled the transfer case with the car raised in the front and had to lower the car to level and check to see if fluid was coming out. I did that about 3 times until I saw a little bit of fluid coming out and was good to go! No leaks so far!
Will update if anything changes.

QUESTION: I've heard that there is a cavity in the transfer case where the fluid can't get to so filling it up the way I did isn't the "best" way to do it. After driving the car I was told that is when the fluid can make it to the cavity but then I have to Check the transfer case and fill it a little more to get it to the right amount. Is this true? Or is what I have done Just fine?

 

[1990TSIAWDTALON]

I say you are fine....for now. Next opportunity that you get after a drive around the block, check it again and look for fluid. It is something to keep an eye on, just as normal maintenance, like checking the oil. If you are satisfied after a couple of checks then you can not worry so much about it but still do a periodic check, they do let fluid "disappear". Hate to have one lock up on you, it hurts more than the transfer case when it happens.

 

[ishnish]

Thanks Marty! Yeah I checked it after the drive and it was fine but I will constantly check for leaks period on my car because it always had a leak problem when I bought it from the last owner. This is the first time ever it actually has no leaks ever since I've owned it... For now...

 

[1990TSIAWDTALON]

Glad she is leak free for the time being. You can focus on other things!

 

[pauleyman]

Thank you guys all for the replies.

Yesterday I removed the fill plug and the car's front was raised and it was still draining from the fill plug! So definitely over-filled. Then I removed the drain plug and it felt pretty dang loose be wise I was able to take it off pretty easily in comparison to the fill plug which took quite a bit of elbow grease.

Anyway, the fluid coming out was brand new which sucked but whatever. I went to a local shop and got some heavy shockproof and then got brand new copper crush washers, one was a 16.4mm since that was the closest to 16mm for the fill plug, and the other was an 18mm which was closest to the 18.2mm for the drain plug.

I filled the transfer case with the car raised in the front and had to lower the car to level and check to see if fluid was coming out. I did that about 3 times until I saw a little bit of fluid coming out and was good to go! No leaks so far!
Will update if anything changes.

QUESTION: I've heard that there is a cavity in the transfer case where the fluid can't get to so filling it up the way I did isn't the "best" way to do it. After driving the car I was told that is when the fluid can make it to the cavity but then I have to Check the transfer case and fill it a little more to get it to the right amount. Is this true? Or is what I have done Just fine?

Next time I would suggest draining into a clean pan. At least then you can reuse it.

 

[ishnish]

Next time I would suggest draining into a clean pan. At least then you can reuse it.

Someone actually suggested that to me. Problem is I didn't have a clean pan or anyway to transfer it back into the case. It's okay though