[limitedman]

I have a 97 GCL, with the 242. It's leaking where it's bolted to tranny. Is there a gasket there? Or use silicone? Doesn't look like that bad of a job. Anything else I should do with the transfer case removed? Seals?

[-Joe-]

No gasket between the transfer case and transmission.. Should be a notch there to let you know one of the seals in there is leaking though. They dont share fluid so no seal/rtv is needed to mate them together.

You might as well replace both seals since its obvious one is leaking. Either the transfer case side or the transmission side seal..

[limitedman]

I suppose special tools are needed to replace the seals?

[Vestjam]

There is a seal on the transmission side. The shaft from the transfer case mates to the shaft on the tranny when the two are connected. It's a fairly common failure point for leaks.
You can use a 'seal puller' but a long screwdriver will work to pry the old one out. I've even heard of people running a drywall screw into the old seal face and then pulled it out that way.
Be carefull not to run the new seal in too deep (past flush with outer edge).
Put some axle grease on the inside of the new seal to help keep the spring inside the seal in place. If you hit it wrong with the transfer case when you are putting it back together, that spring can possibly dislodge and you are back to leaking.
On a 42RE tranny the seal Mopar part number 4269956AB It will have green outer edge.

It's a very straight forward process, it just takes a few hours. The top bolt for the transfer case is a pain to get at. I use a stubby 9/16 with a built in ratchet for that bolt. Support the transfer case with a jack... it's heavy! You will have to drop drop both drive shafts out of the way. Mark the ends before you remove them so you can match them up later.

[Virmagicus]

Originally Posted by Vestjam

There is a seal on the transmission side. The shaft from the transfer case mates to the shaft on the tranny when the two are connected. It's a fairly common failure point for leaks.
You can use a 'seal puller' but a long screwdriver will work to pry the old one out. I've even heard of people running a drywall screw into the old seal face and then pulled it out that way.
Be carefull not to run the new seal in too deep (past flush with outer edge).
Put some axle grease on the inside of the new seal to help keep the spring inside the seal in place. If you hit it wrong with the transfer case when you are putting it back together, that spring can possibly dislodge and you are back to leaking.
On a 42RE tranny the seal Mopar part number 4269956AB It will have green outer edge.

It's a very straight forward process, it just takes a few hours. The top bolt for the transfer case is a pain to get at. I use a stubby 9/16 with a built in ratchet for that bolt. Support the transfer case with a jack... it's heavy! You will have to drop drop both drive shafts out of the way. Mark the ends before you remove them so you can match them up later.

X 2 ... also make sure you insert the seal, flat side toward the TC.

[limitedman]

Originally Posted by Vestjam

There is a seal on the transmission side. The shaft from the transfer case mates to the shaft on the tranny when the two are connected. It's a fairly common failure point for leaks.
You can use a 'seal puller' but a long screwdriver will work to pry the old one out. I've even heard of people running a drywall screw into the old seal face and then pulled it out that way.
Be carefull not to run the new seal in too deep (past flush with outer edge).
Put some axle grease on the inside of the new seal to help keep the spring inside the seal in place. If you hit it wrong with the transfer case when you are putting it back together, that spring can possibly dislodge and you are back to leaking.
On a 42RE tranny the seal Mopar part number 4269956AB It will have green outer edge.

It's a very straight forward process, it just takes a few hours. The top bolt for the transfer case is a pain to get at. I use a stubby 9/16 with a built in ratchet for that bolt. Support the transfer case with a jack... it's heavy! You will have to drop drop both drive shafts out of the way. Mark the ends before you remove them so you can match them up later.

Thanks much. Does the TC have a seal also?

[Virmagicus]

Yes , it slips over the input shaft end. Get a seal puller or drill a small hole and insert a drywall screw or equivalent into the hole and pull it out. You may have to drill a hole on each side. I use a small wood block to insert the new seal. Just make sure you have a nice flat edge and tap it in evenly until it is flush. Image shows 249 but they are the same.