Here's the story:

After replacing my clutch I had a leak from the passenger side axle seal (transfer case side). I replaced that and all was well for the past 2 months. I changed my oil yesterday. I started the car to get all the new oil flowing around so I could check the level more accurate. I heard the ever so slightest weird noise after I started the car and let the clutch back in (car in neutral). It was so slight it didn't register as abnormal. When I was retrieving the oil pan I noticed a 6" puddle under the car. I wiped a finger in it and yep, it's transfer case oil.

So I get under the car and see the TC oil covering my inner passenger cv boot. The axle seal itself didn't seem to be leaking. So I cleaned it all up, filled it back up, and went for a short drive to see if I could get it to leak. I came back and looked with no fluid under the car. I went for a longer drive and checked again, no leaks. I let the car sit over night and then drove it somewhere in the morning and checked when I got back, no leaks.

Car sat again over night and I checked the level it seemed a little low but it's hard to know for sure when you only jack up the front of the car (since the level check is on the back-half of the TC). I did notice that when I took the fill plug out I heard a whoosh sound like air was exiting the TC. I filled it up again(didn't really take anything).

Is there a vent in the TC that should allow this air out (in?) or not? Also the car sat over night when I checked so it was completely cooled down.

-Thanks

 

Every gearbox has a vent.

 

So what your saying is possibly mine is blocked?

 

maybe, the white plug on top of your t-case is a vent and also in case of an overflow, so check that.

 

I took off the white plastic cap. There is some type of cap that I guess would have a check valve in it. I pressed (or pulled can't remember now) and it relieved some pressure. I don't know the correct operation of this some I'm kinda shooting in the dark here. I saw there are 4 bolts holding the plate the valve is in. Can I just remove that plate without causing anything inside to come apart? Then I could get a good look at the valve.