Transfer case leak

[Garys99-3/4ton]

The transfer case on my 99 Silverado keeps springing leaks from it. One person said that the keeper that holds the pump motor from spinning inside of the case probably broke and the pump itself is rubbing on the inside of the case and causing the leaks. Of course, he worked at a dealer and was trying to get me to buy a new case for about 1200 bucks (that's just the housing, not the whole transfer case). Right now it has worn through in 3 places and I have patched it with 2-part epoxy. It has been holding for a few months now, but I'm not sure how long before another leak shows up. Has anybody heard of this before?....

[SubUser43]

I have a 1999 4WD Suburban 1500 which has devleoped a leak in the side of the transfer case. The leak is on the right side approx. 8 in from the back end of the unit - just before the beginning of the tapered section. A small hole has developed which I am attempting to epoxy. I don't know how successful this will be, however, since the hole appears to have been made by movement of some kind within the case itself. What are my replacement or repair options?

[SpitAndDirt]

This sounds kind of out there, my brother has worked at dealerships for about 6 years and he has come across some vehicles that develop porosity problems. Literally, fluids will find their way through the metal because of how it was cast. I remember one instance that a cylinder head on a new 5.3L had to be replaced because of metal porosity. It would not surprise me that if your leaks are not cause by rubbing of internal parts, it could be case porosity or bad machining of parts, both which I believe would be covered under some kind of warrenty I believe. Unfortunately, check with the stealership service writers for Technical Service bulletins. Check with a service tech also, as he really is your friend, becaue he only gets like 15% of the labor you actually pay to the dealer. You are his bread and butter if you see what I mean. Hope this gives you some new ideas. -Chris