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Transfer Case Bottom Cover Leak

Old Sep 27, 2025 | 05:23 PM
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Old Sep 27, 2025 | 05:28 PM
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Old Sep 27, 2025 | 06:49 PM
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Originally Posted by CharminULTRA
The fuel pump on D2s typically goes bad between 100-150k miles. Replacing mine fixed my issues with needing to hit the starter twice.
Have had four trucks over 215k, none needed a fuel pump.
 
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Old Sep 27, 2025 | 06:52 PM
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Originally Posted by Casualfriday
Update: at the beginning of July, I had an Indy LR shop drop and reseal the transfer case. They actually had to drop and reseal twice as they saw it was still leaking after the first time reinstalling. I’ve put about 1000 miles on it since (mostly around town) and it’s been dry.

This Friday I bailed on my father in laws birthday to go to my first MAR (he wanted me to go, wife is still pissed). Drove down (125 miles), paid, set up camp, and got about 2 hours of green and yellow trails in low range before I realized the tcase was leaking again. Unfortunately I didn’t have the fluid or tools with me to just keep it topped off and was in a bad mood as I just paid $2k less than 3 months ago to have it good to go for MAR so I ended up just packing up and went home. I’m sure I could have kept driving for the weekend and been fine but I’m an anxious guy and figured better safe than sorry. Huge bummer though.

Anyway it’s not leaking from the intermediate shaft anymore. I think it’s leaking from the main input seal where it connects to the trans and definitely on the rear cover plate. Pictures below for reference. What do y’all think? Take it back to the shop and have them redo it again? Throw some blue devil in there and hope for the best? I think I can remove the rear cover plate without removing the tcase to throw some rtv on there but the tcase has to be dropped in order to replace the main input seal which is where the majority of the fluid is coming from.
I would make them do it or refund your money, who was the shop? Consider Sportscar workshop in Richmond area going forward. ROAV sponsors.
 
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Old Sep 27, 2025 | 08:41 PM
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Originally Posted by Extinct
I would make them do it or refund your money, who was the shop? Consider Sportscar workshop in Richmond area going forward. ROAV sponsors.
Yeah that’s what I was thinking, thanks for the backup. The owner is a good guy so I’m hoping he’ll take care of it. I’m up in Northern VA, I’ve heard good things about Sportscar workshop and would try them out if I was closer.

Too bad I left early, I hoping to meet you Extinct! Could have shown you the nice new see through plug on my transfer case you made showing how low the fluid was in it lol. Next time!

 
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