Allison 5sp: Transfer case leak

[DAKOTAKIDD]

Hey guys. Was doing a service today and when I was under the truck having a look around I seen some oil leaking from the transfer case. It was all on the lowest point. I immediately though about the pump rub but didn't see any holes and there wasn't much fluid on the case. The skid plate was dry. I have some pics of where the oil was after I wiped it off. Also in one of the pics it looks like a small crack but no fluid leaks consistently from it.

Do I have a bad gasket or something else. I am going to check the fluid level tomorrow




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[DAVe3283]

It looks like someone over-tightened the drain plug at one point and cracked the housing. If it doesn't leak, don't worry about it, that part isn't structural.

As for the other leak, that could be the gasket between case halves. You could pop it apart and re-seal it, but I am not sure it is worth the trouble if it is just weeping a little.

 

[DAKOTAKIDD]

I checked today and there was a little bit of fluid on the lower case. I checked the level and it was good. Never had to add any. Check the torque of the drain plug and got a little bit. Not much. I hope that's the fix but I doubt it.

I will watch it and start looking into a case and pump rub kit. Any recommendations ?

Thx guys


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[Alisobob]

Most folks buy another GM ( zinc pot metal) housing, and put a pump rub kit in it.

The better solution is to buy a aftermarket aluminum housing, that doesnt need a pump rub kit.

https://www.amazon.com/Dorman-917-561-Transfer-Case-Housing/dp/B00BJ4EFXE

Just make sure you order the correct one..... and your done.