A source of an ATF leak on my transfer case is the speed sensor, and the speed sensor adapter. Each has an O ring seal. My question, will the pinion shaft that goes into the adapter, fall inside of the housing, if I remove the adapter to replace the O ring on it ??

Anyway, the manual says not to remove the adapter when removing the sensor. Fine, if it's just the sensor removal, but it doesn't mention if there is an issue when the adapter is removed. It appears the the little pinion shaft has a support bearing in the opposite side (inside) of the case. so If I pull the adapter out, with or without the pinon shaft, can I get it back together ??

Sorry for the long question !! (no I'm not !)

 

I removed the sensor and the adapter. The adapter has a speedo gear on the end of it, and nothing like what the service manual shows. Got some new O rings for it & gonna put it back together Wednesday...
Next seep/leak is farther forward from what I can tell, but it may be from an old valve cover seep. Gonna wash the engine & trans down with my engine cleaner gun & mineral spirits.. then see if any more leaks show up...

 

If you have some silicone grease handy apply a little to the o-rings before installing.

 

You'll be fine removing the entire assembly... take a picture of its orientation so you clock it correctly when putting it back on

 

I put it back together today. Luckily there is an O ring and seal place nearby, and they matched up the old parts. No big deal getting it back in.

In other news..I noticed this evening that with the heater blower on high, the volt meter drops down quite a ways, just about the to low red area on the gauge. Not sure what that's about. Once in a while the voltage drops off like that. I guess I'll have to check all the visible connectors in the harness etc...Dam good thing I have a warm shop to fix this dam thing !

 

High resistance somewhere, heat is a tattletale if you don't have a DMM.