Transfer case rear casing

I am debating on whether or not I should attempt a DIY on my transfer case... there's about a 3 mm hole in the rear casing and it's leaking fluid out... I'm going to check the manual for the fluid type, but I've heard of a newer fluid that is now being used in the cases... the dealer called it "Quadratrac" but I did a search online and came up with "Autotrac II" as the desired fluid type... can anyone point me in the right direction as to which fluid would be the most desireable to use in the transfer case? Also, if anyone has any installation tips for removing and re-installing the back half of the transfer case it would be greatly appreciated... from what I can gather, the rear drive shaft seal and the shaft itself has to be seperated from the transfer case and the rear casing removed from the case and re-installed... the rear casing is $344 but the dealership wants to charge me about $900 to do it in the shop. I just can't justify spending $600 in labor to replace something like that...

Thanks!

If the hole is not in the area of stressed material or structure...ribs or gussets, an epoxy putty applied to a cleaned and prepared area will stop the leak without removing the case if you can get to the area.
Rough up the area with 80 grit sandpaper, clean with a solvent that leaves no residue, you can read the back lables on brake cleaners at your local auto parts or put some acetone in a squirt bottle...rags leave lint..let dry then mix and apply epoxy putty and let sit for 24 hours. This method works on drag race cylinder head intake port & intake manifold modifications I do regularily.
For transfer case lube, I'd just go to the dealer and get what they recommend since a non leaking transfer case needs little fluid attention other than an occasional level check...my '92 with original fluid & 177k and my '97 & 100k.

Thanks a lot... you've been really helpful. Regarding the epoxy though, the dealership put some JB Weld (and charged me $75 for it ) and it didn't stick... I looked at it last night and there's a little crack in the epoxy.. I was thinking of sanding down and JB Welding again to see, but I don't know if this would even work... wouldn't hurt I guess... I'll have to take a look at where the crack is to be sure; hopefully I won't have to replace the rear casing.

If the JB Weld is cracking then maybe vibration or thermal expansion is doing it. Maybe if you just smeared some red RTV sealant over what's there now.

I hadn't thought of that... I smeared some more JBWeld on there last night but I have some red RTV in my garage and I'll give that a try.. thanks a lot!

Did the red RTV do the trick? I have the same problem on my 98 Bravada. Need advice and help....

You might have to park it on a hill to get the fluid away from the hole but the RTV stuff should seal it up.
The question has to be asked, what's holing yer case? Does it look like something's beating it up from the inside or is it fracturing from torsional twist like the drivetrain is getting into a bind from tight turns?

my problem with my transfer case seems similar. i replaced the rear seal on the drive shaft about a month ago. and late last week, i started hearing the tell tale signs of fluid escaping. previously, as in starting in july, it was bone dry and i filled it up and had to keep filling it back up every month or so till i had my cousin to help me. so, we changed the seal and either the seal is still leaking or it is leaking somewhere else. from what i can see there are a bunch of bolts in the middle of the transfer case that hold it together. the front side of those bolts are clean and show no signs of leaking. the rear side is very dirty. would your suggestion be to put red rtv on that line and hope for the best? could it be leaking out the fill or drain plugs? thx for your suggestions

You gotta find your leak source. What year Bravada? Can you see or find the vent line? Does it hang down or does it disappear up on the firewall? Is the vent line stopped up...that would allow pressure to build when the motor/trans/transfer case warms up and push fluid out the seals.

my problem with my transfer case seems similar. i replaced the rear seal on the drive shaft about a month ago. and late last week, i started hearing the tell tale signs of fluid escaping. previously, as in starting in july, it was bone dry and i filled it up and had to keep filling it back up every month or so till i had my cousin to help me. so, we changed the seal and either the seal is still leaking or it is leaking somewhere else. from what i can see there are a bunch of bolts in the middle of the transfer case that hold it together. the front side of those bolts are clean and show no signs of leaking. the rear side is very dirty. would your suggestion be to put red rtv on that line and hope for the best? could it be leaking out the fill or drain plugs? thx for your suggestions
this thread is 2 years old. please refrain from posting in old threads in the future. feel free to start a new thread.