Front Differential and Transfer Case?

So it turns out my clunk is being caused by my front differential. Looking to pickup reman ATP differential as it is the most cost effective $1222. Jasper wants $2222 so no thanks. This repair is a must.

While having the truck inspected it turns out the transfer case was overfilled. Indicating a bad trans or transfer case seal? Fluid is obviously flowing from the transmission to the transfer case. This repair is also a must.

Oil pan has a leak. More like oil seepage. When the diff is pulled I will have him change the gasket. Front main is seeping as well. Thoughts on the front seal? I never have to add much so I know the "leaks" aren't bad.

I am highly considering a reman/rebuild transfer case due to the age of my current one. Im sure the chain is stretched and I am not sure if the overfilling has caused other issues. Thought's? I found this one.

https://www.ebay.com/itm/172412225267

Anything I am not thinking about or should be aware of?

@swathdiver @Doubeleive @iamdub

for $1222 on a front differential I would just ****** a used one from the junkyard I could go thru 4 or 5 used ones and still be ahead of the game, if you look at them close you may even find one that has already been rebuilt you can usually tell by the amount of sealant used, they are pretty easy to pull and they usually are priced pretty reasonable.
my transfer case on my 00 went over 300k and I beat the crap out of it, I don't know about the seal or if it is serviceable without pulling the transmission
front seal I don't think is all that difficult but the right tools are needed

I'm not the most familiar with the 4WD systems on these, so the only real input I can give is for the engine seals. It's smart to have the oil pan gasket replaced when the front diff is out. Replace the pickup tube O-ring while you're in there. If the trans is coming out, replace that rear main seal. The front seal can be replaced without removing the cover, which means the water pump, etc. can stay in place. But, getting the old seal out is a real PITA. Personally, I just remove everything so it all gets new gaskets. Just be sure that front cover is properly aligned or your new seal will leak soon. If you have the front cover off and it's a high mileage rig, a new oil pump and timing set isn't much more work or expense.

I would probably just change the diff and the fluid in the tcase. The case in my silvy has 396k miles on it, so yours is probably ok.

AWD (not 4WD) transfer case, right?

There is a reman front diff available on RockAuto too. It’s a bit cheaper that the ATC unit.

@Fless

Yes it is Awd.

Massfloefi said:

I am highly considering a reman/rebuild transfer case due to the age of my current one. Im sure the chain is stretched and I am not sure if the overfilling has caused other issues. Thought's? I found this one.

https://www.eba

Massfloefi said:

So it turns out my clunk is being caused by my front differential. Looking to pickup reman ATP differential as it is the most cost effective $1222. Jasper wants $2222 so no thanks. This repair is a must.

While having the truck inspected it turns out the transfer case was overfilled. Indicating a bad trans or transfer case seal? Fluid is obviously flowing from the transmission to the transfer case. This repair is also a must.

Oil pan has a leak. More like oil seepage. When the diff is pulled I will have him change the gasket. Front main is seeping as well. Thoughts on the front seal? I never have to add much so I know the "leaks" aren't bad.

I am highly considering a reman/rebuild transfer case due to the age of my current one. Im sure the chain is stretched and I am not sure if the overfilling has caused other issues. Thought's? I found this one.

Click to expand...

Massfloefi said:

https://www.ebay.com/itm/172412225267

Anything I am not thinking about or should be aware of?

Click to expand...

y.com/itm/172412225267

Anything I am not thinking about or should be aware of?

Click to expand...

@Massfloefi

I have a good used transfer case that came out of an awd 05 escalate you can have for $300 bucks plus shipping. I have it listed on Offerup for $350

Doubeleive said:

for $1222 on a front differential I would just ****** a used one from the junkyard I could go thru 4 or 5 used ones and still be ahead of the game, if you look at them close you may even find one that has already been rebuilt you can usually tell by the amount of sealant used, they are pretty easy to pull and they usually are priced pretty reasonable.
my transfer case on my 00 went over 300k and I beat the crap out of it, I don't know about the seal or if it is serviceable without pulling the transmission
front seal I don't think is all that difficult but the right tools are needed

Click to expand...

I hear you on the price. Not thrilled but the quote I got for a jasper made it seem like a bargain.

I would be more comfortable with removing it myself if I had another hand. Lift wouldn’t hurt either. It good to hear that I could probably skip fixing the seal that causing trans fluid to bypass and fill the t case.