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Noticed a buildup of oil or grease at the transfer case. Any ideas what’s causing this? Thanks!

Hello, how are you? Check if the wheel has any axial play, as there should be a seal between the disc and the transfer case. Check if the fluid has been replaced and if it has not exceeded the limit, a broken bearing, or anything like that, which could lead to this problem.
even the sensor retainer behind the disc may be broken.

 

It’s definitely a do not ride until fixed failure — oil on tires is bad, low oil in final drive is bad. Might search for YouTube videos to determine if you are up for the repair.

Here is a video that shows your later deal as well as the earlier one.

 

Best case the oil seal part #6 of the exploded parts view in post #2 is failed and needs replaces. This will still require taking off the hub that is press fitted onto the splines. It will not slip right off. If you are going to attempt to do this yourself I'd encourage you to search YT and watch a few videos on how to remove/reinstall the hub on the spline.

If you find the rear hub has more than 1mm of play in it, time for a rebuild. If that is indeed what is needed I'd reach out to Anton Largiader southern Virginia. He''ll set the drive up better than new.

 

This site is such a great resource, thanks for the responses! removed the wheel to look around and looks like a bad o-ring at the sensor input. Cheap and easy problem to fix! I’ll change out the oil while I’m in there. thanks again!

 

Once you get an new O-ring or get the old O-ring sorted I get the gear oil cleaned off the bike and then get a liter of 75W-90 GL5 gear oil and change the gear oil to verify that you have exactly 180ml and only 180ml of gear oil in the rear drive. Did I mention that you only use 180ml of gear oil in the gear drive?

Some of the best ways to measure out and dispense the gear oil is with the use of a hair dry bottle that has graduations cast into the side the bottle. The angles tip makes it sure easy to dispense into the fill hole.

 

Yes, that’s the plan. I have a graduate syringe with tubing attached. Hair die bottle is a good idea, thanks!