I’ve got a ‘01 Ram 2500 V8 and I recently noticed my transfer case has a leak after seeing a puddle beneath the truck. I wiped it down and the output shaft seal and took it for a spin after filling it with fresh fluid. It appears that the gasket between the transfer case and the transfer case rear extension housing is the problem. I haven’t been able to find any information on anyone swapping it out. Anyone here ever done it? Seems pretty straight forward. I figured I’d drop the drive shaft and then swap it out. The gasket is pretty cheap. I might go ahead and replace the output shaft seal while I’m at it.

 

Yeah, replace the gasket and seal. Use a thin coat of RTV on both sides of the gasket as well. While you are in there, take a good close look at the snap ring on the output shaft, that holds the shaft/bearing in the right spot. Those are notorious for coming out/breaking, allowing parts to move, that shouldn't. Bad things happen quickly. Transfer case saver is the cure for that problem. Might want to have one on hand, just as insurance, if nothing else.

 

Thanks for the heads up on the snap ring. I'll go ahead and buy one.