Ok guys, I have a good one for ya. Here it is. 97 4door. 4x4 works great when cold. after I drive for 1/2 hour or so, when i try to switch from 2hi the fuse pops. I can pop fuses all day long after that, but if I let her sit for an hour, change the fuse, switches no problem. Also, there is a very small leak (drip) from the seal between the transfer case and tranny. So, I take it to my buddy shop, and pull the fill plug in the trasnfer case, it spews tranny fluid like crazy(from the fill). So here is my guess. I think that the seal between the tranny and TC is gone, causing the fluid to push in to the TC, causing tonnes of pressure, and then dripping out of the gasket. after i let her sit, it slowly goes back into the tranny where is should be. Now i am mechanicly retared, so this is just how i picture it in my head. anyone else have an idea? If I am right and its the seal/bearing, how hard is this to change in my garage? how expensive is this? should i use the tranny stop leak crap? any help would be great, thanks guys! Mike.

 

Dont use stop leak it wont help the rubber seal failure, I had mine go at really low miles,but it was changed under warranty. I dont think the fluid will migrate back into the tranny unless you are tipped toward the tranny. Im not sure if there is a diy article on this but there are many post about the same issue around here.