Hoping someone can help me with a transfer case leak issue.
I was noticing that my car would buck at around 15mph, usually just after shifting into second gear. I first checked the transmission fluid. It was full, and nice and pink. I searched for a potential cause, and found posts about abs check, and disengagement of front wheels around that speed. Anyway, since I have 122k miles on it, and don't know the service history prior to 110k miles, I decided to change the transfer case and differential fluids. The case was damp (has been leaking), and the fluid badly burnt. Only 20 oz, or so came out, but the plug didn't have much grime on/in it. Refilled with a little over a quart of fresh fluid. Test-drove, and the buck was barely noticeable. It was gone with the drive to work the next day.
Now, a week later, the buck is back. The transfer case is wet, and a couple drops on the driveway. Expected front or rear seals to be the source, but both are dry. Once I was able to get far enough underneath, it appears to be leaking from around the electrical connection, right above the fill plug. The electrical connector is loose, and can jiggle/twist around a bit in the housing. Searching the service manual, I see that there is an o-ring seal on the inside of it, and a clip outside holds it in place. Anybody else dealt with a leak at this location? It appears that in order to change the o-ring, the transfer case has to be removed and disassembled. If it's the connector plastic is broken, I'm probably screwed, since it's part of the coupling assembly, which is discontinued.
I really don't want to pull the transfer case unless I absolutely must, so any advise is greatly appreciated.
I was noticing that my car would buck at around 15mph, usually just after shifting into second gear. I first checked the transmission fluid. It was full, and nice and pink. I searched for a potential cause, and found posts about abs check, and disengagement of front wheels around that speed. Anyway, since I have 122k miles on it, and don't know the service history prior to 110k miles, I decided to change the transfer case and differential fluids. The case was damp (has been leaking), and the fluid badly burnt. Only 20 oz, or so came out, but the plug didn't have much grime on/in it. Refilled with a little over a quart of fresh fluid. Test-drove, and the buck was barely noticeable. It was gone with the drive to work the next day.
Now, a week later, the buck is back. The transfer case is wet, and a couple drops on the driveway. Expected front or rear seals to be the source, but both are dry. Once I was able to get far enough underneath, it appears to be leaking from around the electrical connection, right above the fill plug. The electrical connector is loose, and can jiggle/twist around a bit in the housing. Searching the service manual, I see that there is an o-ring seal on the inside of it, and a clip outside holds it in place. Anybody else dealt with a leak at this location? It appears that in order to change the o-ring, the transfer case has to be removed and disassembled. If it's the connector plastic is broken, I'm probably screwed, since it's part of the coupling assembly, which is discontinued.
I really don't want to pull the transfer case unless I absolutely must, so any advise is greatly appreciated.