Hi Gang-

I've got a leak from my extension housing on a 1998 4x4 expedition with E40D tranny. I've linked to a pic below. My quesiton is - does this look like a leak from the gasket between the housing and the transfer case or a leak from the seal on the tail-shaft? (I think the gasket between the housing and case).

Also - is it easy to remove the extension housing? Does it just unbolt and come off so I can replace the gasket? What about the tail shaft and any gearing inside? (I'd just go for it but this pic is a few months old now and I've got it back together. I'm hoping to get an opinion before I dive in again and get greasy.)

Thanks for the help.

 

Looks like it's leaking between the tail housing and the main case to me. If I'm remembering correctly it's just sealed with silicone. If it were the tailhousing seal leaking it would be clean and dripping right off the back which usually means the bushing in the tailhousing is worn. It wouldn't hurt to put in a new bushing since the housing has to come off anyway, but it doesn't look like that's your problem.
The tailhousing just unbolts and pulls off. If you have a speedo cable on the other side you'll need to take that out first. Now for the part I can't quite remember: On some Expeditions the housing interferes with the floor before you can pull it far enough back to get it off. I'm not sure what makes the difference, the floor itself, t-case position due to trans differences, I can't remember. But if it hits you'll have to drop the trans and t-case a little to get the housing out.

 

Look on the other side of the extension housing. There should be a wire going into it on the upper side and the hole is sealed with silicone. Check to see if the silicone is still sealing the hole.

Regards

Jean Marc Chartier

 

Well I took the extension housing off and re-sealed it. It was low on fluid and not shifting out of 4wd. Now it shifts ok.
Thanks for the tip on the wire. I need to go back and seal that hole as I didn't when I put it back together.