In an attempt to stop mine from leaking, while we have the transmission out I have done the following, it is hard to tell exactly where the leaks are since it looks like the transfer is leaking everywhere
This trans has been out before very evident by condition of bolt heads, use of zip ties etc.

replaced the torque converter pump seal ( not leaking but cheap so worth doing)
Both front and rear output flange seals that were leaking no play in bearings
Resealed bottom cover with the right stuff rtv
Pulled the cdl , replaced o ring on the shaft and resealed flange with right stuff( flange o ring beat so reused with sealer since I didn't have one) the bolts appeared to have red locktite and I snapped one had to drill and re tap real mess, should have used impact to remove em

 

Cdl



Trans leaks



Hard to tell what leaks so I assume everything leaks

 

Found the source of my main leak I think, the CDL lite switch, was in not even finger tight, rave shows a jamb nut I am missing but gives no instructions on adjusting it, too tight and the CDL does not work, anyone give some insight?

 

Installed a nut on switch, thread sealer, screwed in, used a volt meter to set depth making sure the CDL properly functioned then tightened jamb nut against case
Final result

 

Here are some pics high low shifter

 

Also resealed the hi low detent?



And ordered the shifter seal rovers north, ab couldn't get it, this one is brittle just like all the o rings I removed

 

Also resealed this detent thingy? Replaced trans filter with a kit I bought 5 years ago,never wanted to pull the cross member to do it

 

Also removed what was left of the transfer case drain we broke off over the winter, got a new drain bolt at pep boys M12 X 1.50 drain bolt $3.99?

All that was left in the case was hollow threads and the magnet

I realty hope after all this I never have a leak on the trans and case again, all o rings I am using are green or nitrle

 

It's common to punch the pin out of the Shiftlock Solenoid. When the solenoid fails you'll be digging through the tunnel to get low out of the transfer case. Up to you. About as fun as warm beer.

If I remember right you have fairly high mileage on your truck, when's the last time the tranny fluid was changed? You know the drill, once you replace the filter AND fluid on a high mileage tranny that hasn't had regular maintenance it's bound to quit sooner than later. Been there, done that....... With the ZF's it's usually the governor or valve body, steels and clutches will be like the day they where made.

Also one last thing, don't bang the torque converter against the pump, you'll have a bad day. Usually busts the pump cover, damages the pump. Built like a swiss watch.....

 

I flushed the trans a few years back and been fine so fingers crossed it still works, info on the converter and pump is real good to know

Trans pan was clean inside, magnet in pan was pretty much clean too

I knew there was something on that solenoid but could not remember, probly can't get it unbolted now, that right stuff rtv is insane