You can fix that leak (which is a common one) by draining the transmission, removing the transfer case, removing trans crossmember, then removing the tailhousing. Cleaning everything up and resealing it with a thin layer of gray RTV silicone on both machined surfaces, bolting them back together. Wait about and hour or two for the RTV to harden up, then refilling the trans. This is how you replace the tailhousing to trans seal on a manual.
Since you are planning on new clutch and slave cyl, it's easiest to do the fix while the trans is out of truck. Process is still the same.
Originally Posted by cheese_man
you cannot use your present output shaft 4wd tranny to transfer case output shafts are shorter in length
the tranny must be dis-assembled to install the shorter output shaft
I had a very hard time reading this... Next time try to make it clearer for us to read by using punctuation and complete sentences...
If I read it as typed and submitted, none of it is true. The transmission doesn't need touched if he installs a manual transfer case. He already has a 4x4, why would trans outputs need swapped?????
The only concern area is a: does his tailhousing have threaded bosses for the manual tcase linkage and b: the front output of the tcase will determine what front shaft he'll run. Most if not all 98-00 manuals already have the threaded bosses for the linkage. If he's going to run a 90-97 tcase, he'll need a 95-97 Explorer shaft. If '02-03 Ranger (FX4LII) tcase, his stock 98-12 shaft will work just fine. Rear shaft is a non-issue here.