I have a 2010 ford ranger 4.0 4X4 automatic transmission. Since August, the extension housing gasket has blown three times at highway speeds. I have received a number of different excuses and causes of this from various ford dealerships. Among those excuses were the wrong gasket and sealant were used, bad u-joints (which were replaced), and old gaskets were used. I took my truck into a shop today to get some other work done and the mechanic noted that transmission fluid was leaking out of the transfer case, and I just had the extension housing gasket replaced for the 3rd time 3 weeks ago. What could be causing this problem and how can it be fixed because I have looked around and no one seems to have had this problem and no mechanic I've talked to has answers? Thanks
Dude you need to take it back to whoever said they fixed it last... Transmissions are so complex even if you showed me the leak in person I wouldn't be of much help. I've watched thousands of hours of people replacing gaskets on car parts and you could be blind and not get it wrong it's the easiest thing possible to do on a car besides put air in your tires and change the air filter. They obviously didn't do it right and at this point I would find someone to do it and send whoever tried to fix it three times the bill and say if you don't pay for it that you'll sue them. Anyone can >100$ can go down to the county clerks office and file a suit and that's exactly what I would tell them and do if they refuse. This is exactly why I tell people to never get their car worked on at the dealership. FORCE THEM to make it right because your only other option is to have someone else fix it and you front the bill again and take it in the ass. GL man... It makes me want to vomit blood when I hear stories like this. Tell everyone you possibly can where you live about what you had to go through so hopefully no one you know gets screwed over like that. I bet they pinched the fucking gasket and that's why its leaking. It should not be leaking if you just had it fixed...
Internal bearing failure...if you can move the driveshaft up and down where it exits the transfer case, that's the problem. Also drain some oil and check for metal.
Bent or out of balance driveshaft....check for damage to driveshaft and make sure balancing weights are in place.
