Ok guys, I just had the oil changed in my truck (04 Scab FX4 5.4) anyways, when it was on the lift decided to check the t-case. When I started to pull the top plug and check the fluid, it started to pour out. Now has anyone had this problem and if so what was the fix.

 

Cant say I had a problem like that I just keep breaking mine, on the third one
in 42k

 

Either your doing something wrong or whoever keeps putting them in, is doing something something wrong. .

 

Nope both times the truck was not used in 4 wheel drive for quite some time before they went out. The first time I just backed the truck out of the drive way and it went out. It was a broken fork so I could drive it in 4 wheel drive and it would not make the grinding noise. The seond one was a remanufactured one and was installed correctly (dealership admitted). They gave me a 75k upgraded warranty for free and havent had a problem since.

 

It always did that on my '90 F 150. The truck is still around(just sitting though) with over 160,000mi with original everything including transfer case.
I never really worried about it. I would think that temp would make a difference. It would be hard to over fill: you would have to shoot a lot of tranny fluid in and real quick put the plug back in (unless the truck was pointing down on a hill)

 

If it helps, the truck was at operating temp.This was the first time I had checked the fluids since buying the truck a couple of months ago and was really suprised when I started to pull the plug and it started to gush out. The owner of the shop I was at said that was the first time on a newer F150 that it had happened so I figured it was time to post and see if anyone else has had this problem.

 

Check the transfer case level again in a thousand miles or so. If the transmission rear main seal leaks, it leaks into the transfer case. Both use ATF, so it is a bit hard to tell if it is leaking.

 

the easiest way to check this is get the truck up to opperating temp and check the level of the trans fluid. if it is low then you know that seal is leaking and that means pulling the transfer case.

 

this is a known concern with these trucks... t-case ispulling fluid through the seal out of the trans

 

is this a possible cause for that damn plastic drive gear to get hot and swell up and push over the retaining ball, sending the driver further into the pissed off dimension each time it happens? or is it just me who gets deeper in that pissed off state because ive done it 6x in a matter of a few months.

 

It is hard to believe that tranny fluid could be sucked into the transfer case. You'd have to notice a measurable drop on its dipstick....right?

I just changed out my 05 transfer case fluid and it gushed out of the fill plug as well. I was on ramps and leveled it off to fill back up. I was able to get one good squirt over full and get the fill plug back into place without a mess.

I read on another post that some guys intentionally over fill through the vent tube, but that doesn't sound like a very good idea.

I'll have to keep an eye on the transmission fluid level to see if it goes down over the next 30K miles.

 

I had the same issue. The lube guy changing my oil said the transfer case was way full and the tranny was way low. Turned out being the double lip seal that goes between the tc and transmission. 350 bucks to get it replaced

 

h2oallyear,
Did you take it to the dealer for replacement, or do it yourself?

I'm preparing for a road trip and will bring several qts of mercon V and check the tranny level every fill up. I'll post results upon return.

I'm currious if there is a point where the transfer case cannot accept any more transmission fluid and then starts to leak out, or blow a seal. Anyone heard of that happening?