zgetman

I have just changed out a transmission seal and had to drop my transfer case to get to it. I blew my transfer case rear output seal the other day and was going to replace it while the transfer case was down. The seal I ordered was way to big so I went back on with the old seal so I could get it home. On the way home the transfer case started popping when in 2wd, I tried the other selections and it popped in each of them. As I got closer to home it started popping a lot. Could low fluid cause this or am I going to need to take it apart and check my shifting forks?

dave1123

It's possible the t/case output shaft bearing is worn which caused the seal to leak. Do you have a slip yoke or a flange joint?

zgetman

It is a slip yoke.

dave1123

Just as I thought. The longer shaft will move around enough with a worn bearing to enlarge the slip-joint seal. On the case with the flange joint, the yoke flange pulls right up against the bearing. This is all speculation on my part, but that's what I'm assuming. The other side of that bearing is where the gears engage for direct drive.

zgetman

After much consideration I decided to dig into my transfer case to check out what the problem was. The bearings are in good shape, there is no play, but my front selector fork is shredded. Some how the plastic pieces failed. I guess I should have replaced them when I had this TC open. Lessons learned.

dave1123

Sorry, I wasn't aware you had the t/case open. I thought you just took it out to replace the trans seal. Yes, those plastic slippers do wear out. I guess I wasn't thinking clearly.

zgetman

You was correct in assuming that I just took it out to replace the transmission seal. I just wondered if there was anything else that would cause that popping. But I decided to go ahead and break into the case just to be sure. Its just to bad that it was what I expected.