Hole in the pre-update Selec-Trac Transfer case
 

After getting my car back from service at a local workshop, I noticed a transmission oil leak. I put it down to a top up of transmission oil (this did happen) and potentially an overfill during service. There had been occasional mild spotting in the past on the garage floor, but nothing like this.

It turns out that the leak has been ongoing for a few days and the mechanic found the source. It is a hole in the Selec-Trac xfer case that might be missing some kind of plug. The question is, should the hole be plugged or left alone because it is designed to overflow or release pressure/breather?? If it needs a plug, what kind of plug is it and what is the part called?

I have no photos from the mechanic. My own photos just show an oily mess around the xfer case and nothing specific.

It is a 95XJ Sport. Thanks in advance for any insight.

I have been researching this further.

I think it might be a rubber plug at 6 mins 50 seconds.

After 27 years, this plug would be powder.

https://youtu.be/kuJp2_JnKQ8

Update:

Further to my previous post, that's not the hole.

Apparently there's another apart from the one shown in the clip. , that is not on any of the transfer cases kept by wrecking yards.

Maybe I should ask the following question:

Does anyone know if the Selec-Trac cases have any breather holes, anywhere?

If the answer is no (with no exceptions), then some kind of plug is needed.

What was it about the XJ95 that its xfer case needed this extra hole?

I have a spare 242 from a '96, if I recall correctly, it has a 90 degree metal tube with a rubber hose coming out the top as a breather, I will check when I get a chance, remind me

https://www.naxja.org/forum/showthread.php?t=1138623

Thanks AWG. The above link describes the differences between 242s over the years. If this site is correct, there are differences between 95 and 96 cases, but interested to see where the breather is on the 96.

The pictured 95 model year 242 case in the link above displays two metal pipes on the opposite side. In my case, something must have shot out and has left a machined hole open allowing oil to leak (10cm diameter spotting on the ground). I have no pictures of the location of the hole as it is currently on a hoist.

The car runs fine, the T/case works fine. It is just that we are unsure how to plug that hole!

It wouldn't surprise me if there is 96 t/case in the 95.

The hole has been plugged by the mechanic.

No more leaks. I test drove the car 250km today and it appears to be running well.

just noticed your PM, I will take some pics and stick them up on here, for the benefit of all 242 owners (such as you & myself)

Mine might be shot as well

Being out and on the ground should make things easier