So yesterday I changed out the fluid in my transfer case. My owners manual calls for 2 quarts of ATF. So, before I removed the drain plug, I was going to remove the fill plug so it would vent better. Well, as soon as I removed the FILL plug, fluid came rushing out. I mean a lot. My truck was parked on level ground. Luckily I had a drain pan close enough to where I could catch *most* of the fluid. Anyways, I ended up draining about 4-5 quarts of the transfer case. How was that possible? When I filled it up, 2 quarts put it right at the bottom of the fill plug.

 

The seal between the trans and transfer case is leaking. The trans will pump fluid into the transfer case until it's filled to the top, and sometimes out the vent, too.

The transfer case has to come off to fix it.

 

Thanks Mark. Is this something that would be hard to do myself or should I have a shop fix it?

 

Damn that is a bummer. Removing the tcase is not too hard, it's heavier than whale dik though. If you have any questions let me know, I can't remember anything I should warn you about because I had a buddy help me out and the dude is an alcoholic, drunk before we even installed it.

You will clearly need to remove the front and rear driveshafts to remove. Also, I drained my transfer case before removing it, but if I would not have done that, would the output housing on the tcase leak fluid upon driveshaft removal if fluid was present?

 

just fill to until comes out of the plug.

i agree on the leaking seal too

 

Did that. I'll check the level at my next fluid change (both tranny and transfer case) and see whats up with it. Maybe the factory fills the crap out of em??

 

Eh, not too bad of a job. That NVG case isn't a lightweight though.

Adrianspeeder

 

No, they don't.