I just finished the job! I replaced my rear output shaft seal, front output shaft seal and the paper gasket between the transfer case and the transmission adapter plate. I used a floor jack to raise the transfer case up into place and then slid the transfer case onto the tranny output shaft. Then I tied a ratchet strap to the 2 pipes that run along the inside of the frame and used that to support the front of the transfer case, while I put the big paper gasket on. Took it for a long test drive in 4x4 and have no leaks. Thank you so much! I used a "campbells chunky soup" can to drive the outer race of the seal in and a big socket to drive the inner race of the seal in.
Nice vid S. A , i've just done one these on an '03 envoy , i have re-check my rebuild kit for the paper-hex-gasket , i must have some how missed it. When i originally removed the transfer case, i noted the large rubber O-ring stayed on the front of the transfer case. And the whole time that i was working on the trans, the extension housing stayed on the main trans case. So the seal in front of the extension housing never got replaced. But it's obvious now that my leak is because of a missing paper gasket. If i don't locate one in the rebuild kit, i will just apply Permatex Ultra black RTV silicone sealant. And naturally re-check to make sure the extension housing is not cracked like yours. Thanks so much S.A. , this is only my third automatic trans and this stuff ain't easy.
I know the crack is a must fix issue but why is it leaking oil out of the crack. Shouldn’t the area between the trans and transfer case be dry? There is a seal on the output of trans and input of t-case.
I also would like to know. I believe if there is fluid there either the seal you didn't replace at the back of the transmission was leaking, or the seal at the input of the transfer case you didn't replace was leaking.
Yeah I'm curious about why they crack is it because it's just a high tension area between that transmission and the transfer case and the power or is it faulty casting of the aluminum and it's just a known function a percentage of them are going to fail.?
i just bought my 2005 silverado 2500 like 2 months ago and been driving with i think a seized u joint not knowing why my truck would vibrate hard at 35-45 mph recently noticed my tranny leaking out thought it was just the filter spot but most after further looking i noticed its this part right here thats leaking bad
I thought there was a seal around the shaft on the transmission side to keep the fluid from getting into this extension housing?? Everything I have read up until this video has suggested that the space between the transmission and the transfer case should be dry... Can you elaborate?
Thanks for posting this video, it looks similar to what I imagine is in my 4L60 trans on the NP246. I guess I expected to see you change a transmission output seal shown in the video at 10:13. My extension housing is leaking definite transmission fluid, presumably because that output seal is leaking. I am kicking myself for not looking at that more closely when I had the transfer case off five years ago, it's been leaking for a year or so. As I recall I wasn't sure there was a seal there, and I didn't remove the extension housing. Should I have a typical seal in that area? Love your man-cave!
Hey you actually have a gasket between the TC and the adapter and a large rubber ring seal on the other side of the adapter. You also have that regular output shaft seal in the transmission itself.
I have fluid drip at weep hole in bottom 4L60E 2007 if extention housion is not cracked iyo would the paper gasket or oring be bad? The leak is inbetween the transmission and transfer case already checked transfer case to see if it filled with ATF in case front seal on transfer case is bad and having problems finding right parts and part numbers
Just a little something to add here. You don’t actually have to drain the tc fluid to get the job done with no mess. It wont really drop any oil out. Just my 2 cents
Yes you’re right long as you don’t tip it over to far where the driveline goes in when I was moving it there was leaning it over to far and it leaked all over I also was on some whiskey
You point out a rear transmission case seal (6:36) that "stays with the transmission". I have a 4L60E, but there was no seal present upon removal of the t-case and t-case adapter extension. I did, however, find ATF in the volume between the t-case and transmission (inside the adapter), as, when I removed the adapter nuts, clean ATF ran out. I thought this was major hosed up, as I expected to find a seal there at the rear of the transmission casting, but no, none present. Can you please tell me the year model of this Silverado, so I can (hopefully) locate the seal part number, and possibly see if it will work in the 4L60E that I am working on ? I find it odd that there is no seal present in case rear, and this requires that the t-case input seal be perfect, and that the o-ring and paper gasket also be perfect, to prevent fluid loss at the rear end of the transmission and t-case adapter and t-case. Thanks in advance, and thanks for the video of the cracked extension/adapter. How odd.
Hello, I have a blazer 4x4 1995 4l60e and it leaks from tranny to transfer. So I see the O ring snd paper gasket, but what stops from going to transfer case? He just change the shaft seals, but what about the input of transfer case?
How aggresive/bad was the leak with this crack. I would think thats a low pressure area (within the extension). I ask as mine is pouring fluid in and around my extension. I haven't crack checked it yet but confused and wondering if my pressure is too high due to some other issue. I also had a roar and then it went away right before it dumped fluid
When installing the paper gasket between the transfer case and the extension housing, is it placed dry or is the use of an adhesive recommended? '03 GMC 2500 6.0, 4L80E, 261 HD. Thanks!
A worn loose or seized up universal joint is a likely cause. The vibration in the driveline causes stress on the extension housing causing it to crack.
I have transmission fluid leaking out of what appears to be a Hole on the back of the transmission when I removed the transfer case housing do you have any idea why oil would be coming out of here?
Nice job man. This is just what i needed. I have the same exact issue on a Sierra. Going to tackle this job in a couple hours from now. How many quarts of ATF did you need to refill?
Mine was leaking so I was changing the seal and I noticed mine was cracked on the inside so I bought a new one it just seems so weak should’ve been steal or something I was thinking about somehow strapping a chain across the body of the truck the hold tension off the transfer case
No sir you want that weak link or u f up trans case either side same B's over here I advise to check motor mounts there's always a reason that aluminum snaps
I have a 05 this happen to I had it replaced and about 30days later I was leaking transmission fluid again. I was hoping maybe you could share some calming causes?
There is not supposed to be any fluid inside the extension. All those castings look cracked but the oil that was leaking from from wherever, is either the transmission or the transfer case each having its own fluid. Once the fluid reaches a certain level it will find a way out... The autotracs use blue fluid sometimes and it makes it easy to see which fluid it is. 90/10 it is the rear trans seal over the transfer input seal shaft. if you use autotrac II BLUE fluid then you wil know by the color the trThere is not supposed to be any fluid inside the extension. All those castings look cracked but the oil that was leaking from from wherever, is either the transmission or the transfer case each having its own fluid. Once the fluid reaches a certain level it will find a way out... The autotracs use blue fluid sometimes and it makes it easy to see which fluid it is. 90/10 it is the rear trans seal over the transfer input seal shaft. if you use autotrac II BLUE fluid then you wil know by the color the trans is red
Here’s some advice that will save you more headaches. If you have the 4l80 get the older cast iron adapter from early 90s pickups. The aluminum ones are too weak for the bad design
We're you not worried about the bearing at the back of the trans moving once you take the cracked piece off I've heard that's I big issue when doing it yourself
How strange I'm only hearing about this as being a major problem it seems I've heard more comments about it as it has happened to my 98 Silverado driving at highway speeds I know it's a huge rumble a vibration I came back out of town a leak a little bit of gasket sticking out I tightened it back up thinking most of the gas it was still in a week later I probably shattered it while driving back in town and dropped two or three courts sprayed all over when I tore apart today my housing was cracked all the way around four of the flanges were broke completely away from the studs and we're still hanging on there when I took it apart puzzled but finishing it up tomorrow I'll be taking the housing off and putting my old good one on from another transmission but I never seen a crack like that all the way around like another commenter said. Odd.?
Okay well I did all the same things and I'm going to put it back together tomorrow. I also replaced All u joints Moog front and back d shafts and also new transfer case and transmission 4L60E rebuild in that same time but I wonder if the same extension house was used and had prior stress cracks and caused mine to go out prematurely? And will again Line up the drive shafts marks every nut and bolt and cap it needed to go on the same place and put back together I've had one crack I sure don't want to have three the pain in the ass to do this work jacked up on the ground.
Same here, 3rd extension housing in 6 months. Getting frustrated. I will have my drive shaft rebalanced and start from there. There was always a little vibration going 30mph and then stopped over 40 and started back again at 55. All wheels are good and balanced.
I believe the way it’s set up if you’re hitting big bumps or rough on the truck maybe even kind of jumping it a little bit the way it’s set up The weight of the transfer case is just pulling on that little aluminum piece put some kind of brace on the transfer case and I think you’ll be good that’s what I’m gonna do even hit speed bumps real hard I feel would make it crack the stupid design they did
I just finished the job! I replaced my rear output shaft seal, front output shaft seal and the paper gasket between the transfer case and the transmission adapter plate. I used a floor jack to raise the transfer case up into place and then slid the transfer case onto the tranny output shaft. Then I tied a ratchet strap to the 2 pipes that run along the inside of the frame and used that to support the front of the transfer case, while I put the big paper gasket on. Took it for a long test drive in 4x4 and have no leaks. Thank you so much! I used a "campbells chunky soup" can to drive the outer race of the seal in and a big socket to drive the inner race of the seal in.
Nice vid S. A , i've just done one these on an '03 envoy , i have re-check my rebuild kit for the paper-hex-gasket , i must have some how missed it. When i originally removed the transfer case, i noted the large rubber O-ring stayed on the front of the transfer case. And the whole time that i was working on the trans, the extension housing stayed on the main trans case. So the seal in front of the extension housing never got replaced. But it's obvious now that my leak is because of a missing paper gasket. If i don't locate one in the rebuild kit, i will just apply Permatex Ultra black RTV silicone sealant. And naturally re-check to make sure the extension housing is not cracked like yours. Thanks so much S.A. , this is only my third automatic trans and this stuff ain't easy.
I was able to maneuver a swivel extension to the bolts made life alot less bloody and a little faster. Great video thanks!!
Nice work!
Great video and explanation we need more people like you on here
Thanks!
Thanks a lot!
I've been searching far and wide for this procedure. Not even listed in prodemand
Should have checked the T-case housing for oil pump wear also while off, after going through all that work. Good video for sure!
Thanks! This one had fairly low miles so it hasn't had time to wear through the case yet! lol
I know the crack is a must fix issue but why is it leaking oil out of the crack. Shouldn’t the area between the trans and transfer case be dry? There is a seal on the output of trans and input of t-case.
I would like to know this too
I also would like to know. I believe if there is fluid there either the seal you didn't replace at the back of the transmission was leaking, or the seal at the input of the transfer case you didn't replace was leaking.
Me four
Yeah I'm curious about why they crack is it because it's just a high tension area between that transmission and the transfer case and the power or is it faulty casting of the aluminum and it's just a known function a percentage of them are going to fail.?
The whole repair didn't make sense. The adapter plate is usually a dry area. Transmission output seal leak.
Good video great info thank you
Great video, thanks!
I've changed about 8 of these on various trucks and would love to know why it happens
Driveline vibration is the most common cause. This particular one was driven for quite a while with a worn out U joint that was vibrating.
i just bought my 2005 silverado 2500 like 2 months ago and been driving with i think a seized u joint not knowing why my truck would vibrate hard at 35-45 mph recently noticed my tranny leaking out thought it was just the filter spot but most after further looking i noticed its this part right here thats leaking bad
The transfer case adapter use to be heavy cast iron. I'd upgrade to one of those from an older truck.
I thought there was a seal around the shaft on the transmission side to keep the fluid from getting into this extension housing?? Everything I have read up until this video has suggested that the space between the transmission and the transfer case should be dry... Can you elaborate?
Thanks for posting this video, it looks similar to what I imagine is in my 4L60 trans on the NP246. I guess I expected to see you change a transmission output seal shown in the video at 10:13. My extension housing is leaking definite transmission fluid, presumably because that output seal is leaking. I am kicking myself for not looking at that more closely when I had the transfer case off five years ago, it's been leaking for a year or so. As I recall I wasn't sure there was a seal there, and I didn't remove the extension housing. Should I have a typical seal in that area? Love your man-cave!
Hey you actually have a gasket between the TC and the adapter and a large rubber ring seal on the other side of the adapter. You also have that regular output shaft seal in the transmission itself.
I as well.
i'm assuming the extension housing broke again because you neglected to check the drive lines
I have fluid drip at weep hole in bottom 4L60E 2007 if extention housion is not cracked iyo would the paper gasket or oring be bad? The leak is inbetween the transmission and transfer case already checked transfer case to see if it filled with ATF in case front seal on transfer case is bad and having problems finding right parts and part numbers
Just a little something to add here. You don’t actually have to drain the tc fluid to get the job done with no mess. It wont really drop any oil out. Just my 2 cents
Yes you’re right long as you don’t tip it over to far where the driveline goes in when I was moving it there was leaning it over to far and it leaked all over I also was on some whiskey
You point out a rear transmission case seal (6:36) that "stays with the transmission". I have a 4L60E, but there was no seal present upon removal of the t-case and t-case adapter extension.
I did, however, find ATF in the volume between the t-case and transmission (inside the adapter), as, when I removed the adapter nuts, clean ATF ran out. I thought this was major hosed up, as I expected to find a seal there at the rear of the transmission casting, but no, none present.
Can you please tell me the year model of this Silverado, so I can (hopefully) locate the seal part number, and possibly see if it will work in the 4L60E that I am working on ?
I find it odd that there is no seal present in case rear, and this requires that the t-case input seal be perfect, and that the o-ring and paper gasket also be perfect, to prevent fluid loss at the rear end of the transmission and t-case adapter and t-case.
Thanks in advance, and thanks for the video of the cracked extension/adapter. How odd.
Hello, I have a blazer 4x4 1995 4l60e and it leaks from tranny to transfer. So I see the O ring snd paper gasket, but what stops from going to transfer case? He just change the shaft seals, but what about the input of transfer case?
How aggresive/bad was the leak with this crack. I would think thats a low pressure area (within the extension). I ask as mine is pouring fluid in and around my extension. I haven't crack checked it yet but confused and wondering if my pressure is too high due to some other issue. I also had a roar and then it went away right before it dumped fluid
I just have a question wouldn’t that mean the seal is leaking on the transmission? Bc mine is doing that or just change the housing that is cracked?
When installing the paper gasket between the transfer case and the extension housing, is it placed dry or is the use of an adhesive recommended? '03 GMC 2500 6.0, 4L80E, 261 HD. Thanks!
I just changed the same part and a couple days later it cracked again. Do you know what could be causing it to crack?
A worn loose or seized up universal joint is a likely cause. The vibration in the driveline causes stress on the extension housing causing it to crack.
I have transmission fluid leaking out of what appears to be a Hole on the back of the transmission when I removed the transfer case housing do you have any idea why oil would be coming out of here?
Output shaft seal done
Nice job man. This is just what i needed. I have the same exact issue on a Sierra. Going to tackle this job in a couple hours from now. How many quarts of ATF did you need to refill?
It took around 3 quarts
@@Tomsfoolery. Cool. Thanks buddy
My 04 2500hd was cracked all the way around with chunks missing lol
Wow!
Mine was leaking so I was changing the seal and I noticed mine was cracked on the inside so I bought a new one it just seems so weak should’ve been steal or something I was thinking about somehow strapping a chain across the body of the truck the hold tension off the transfer case
No sir you want that weak link or u f up trans case either side same B's over here I advise to check motor mounts there's always a reason that aluminum snaps
I have a 05 this happen to I had it replaced and about 30days later I was leaking transmission fluid again. I was hoping maybe you could share some calming causes?
There is not supposed to be any fluid inside the extension. All those castings look cracked but the oil that was leaking from from wherever, is either the transmission or the transfer case each having its own fluid. Once the fluid reaches a certain level it will find a way out... The autotracs use blue fluid sometimes and it makes it easy to see which fluid it is. 90/10 it is the rear trans seal over the transfer input seal shaft. if you use autotrac II BLUE fluid then you wil know by the color the trThere is not supposed to be any fluid inside the extension. All those castings look cracked but the oil that was leaking from from wherever, is either the transmission or the transfer case each having its own fluid. Once the fluid reaches a certain level it will find a way out... The autotracs use blue fluid sometimes and it makes it easy to see which fluid it is. 90/10 it is the rear trans seal over the transfer input seal shaft. if you use autotrac II BLUE fluid then you wil know by the color the trans is red
I replaced the extension housing, the seal and gasket on my truck. A week later it cracked again. What would cause it to crack again
Here’s some advice that will save you more headaches. If you have the 4l80 get the older cast iron adapter from early 90s pickups. The aluminum ones are too weak for the bad design
Is it any differnt to do on the allison trans in 05 chevy 3500
We're you not worried about the bearing at the back of the trans moving once you take the cracked piece off I've heard that's I big issue when doing it yourself
Nothing to worry about when just replacing the extension housing.
@@Tomsfoolery. ok thanks!
Is that fkn adapter supposed to fill w trans fluid for some reason I'm missing?
Where did you get the new part from?
I honestly don’t remember but it’s likely I ordered it from Auto Value. I use them more than any other parts store.
Lol my adapter snapped. Going 70 mph down a highway.
Did you find out why I’m having the same problem mines keeps doing it
How strange I'm only hearing about this as being a major problem it seems I've heard more comments about it as it has happened to my 98 Silverado driving at highway speeds I know it's a huge rumble a vibration I came back out of town a leak a little bit of gasket sticking out I tightened it back up thinking most of the gas it was still in a week later I probably shattered it while driving back in town and dropped two or three courts sprayed all over when I tore apart today my housing was cracked all the way around four of the flanges were broke completely away from the studs and we're still hanging on there when I took it apart puzzled but finishing it up tomorrow I'll be taking the housing off and putting my old good one on from another transmission but I never seen a crack like that all the way around like another commenter said. Odd.?
Extension housing another name for transfer case adapter?
Yes
What causes this?
Worn out universal joints cause it. The vibration in the driveline caused by the bad u joint cracks the extension housing.
What would a shop charge for this job? Price range
250-300$ if they dont have to refill the fluid.
Is this the same process for a 98 Chevy Silverado?
Yes
Is this a common issue? And what causes it?
a driveline vibration... like a u jont
@@subieteccould you explain more?
Would that same adapter fit a 4l80 off a 96 suburban?
All the 4 wheel drive 4l60 &4L80's used the adapters. I'm not sure if they've changed over the years.
i have put 3 housing in and the last one was 3 days ago and it’s cracked again any idea why?
Driveshaft out of balance or out of phase and or bad u joint
Okay well I did all the same things and I'm going to put it back together tomorrow. I also replaced All u joints Moog front and back d shafts and also new transfer case and transmission 4L60E rebuild in that same time but I wonder if the same extension house was used and had prior stress cracks and caused mine to go out prematurely? And will again Line up the drive shafts marks every nut and bolt and cap it needed to go on the same place and put back together I've had one crack I sure don't want to have three the pain in the ass to do this work jacked up on the ground.
Same here, 3rd extension housing in 6 months. Getting frustrated. I will have my drive shaft rebalanced and start from there. There was always a little vibration going 30mph and then stopped over 40 and started back again at 55. All wheels are good and balanced.
I believe the way it’s set up if you’re hitting big bumps or rough on the truck maybe even kind of jumping it a little bit the way it’s set up The weight of the transfer case is just pulling on that little aluminum piece put some kind of brace on the transfer case and I think you’ll be good that’s what I’m gonna do even hit speed bumps real hard I feel would make it crack the stupid design they did
I went through that whole fucking video and ya didn’t do the transmission output seal even though the t case was off. Waste for me