I recently installed a new clutch, and now I'm losing gear oil from the seal between transfer case and transmission. The location of the leak is all long the lowest part of the TCase where there are three bolts pictured below.

I'm assuming the seal is junk and will have to be replaced... but here's some strange facts:

We put new fluid in the TCase (OEM) and used the following diagram as a reference (I have an 06 w/ ACD):



The fluid is dripping out slowly but surely. It's been 5 days since we reinstalled everything, and today I put it back on the lift and went to drain the fluid... barley anything came out of the drain plug pictured above, so it would seem I lost all of the fluid...

Now for the kicker...

I go to fill it back up and it just pours out the fill as if it's already full. I tried spinning the wheels and repositioning the plunger that I'm using to force the fluid in, and it just keeps pouring out like it's full.

What am I doing wrong???

 

assuming you just did a clutch job, its likely that the seal actually fell out from between the TC and tranny. its one of those thing you just need to make sure is there every time you put the TC back against the tranny otherwise it leaks.

as for filling it back up. stick your finger in the fill hole and see if you can feel anything blocking it.

 

Thanks... looks like it's gonna be another 3 hours on the lift

 

sounds like you forgot that little rubber o-ring

 

The rubber O ring failing or not being there would leak transmission fluid- not transfer case fluid.

 

Are you sure you aren't losing xfer case oil from the axle seal?

I would use brake parts cleaner to dry up the exterior of the xfer case then watch for the source of the drip.