I have a 06 4x4 screw with a 5.4 and what ever transmission came with that setup. I went in for an oil change today in doing the usual fluid level inspection, buddy found that my transfer case was full way up past the level plug. way full and the transmission dipstick was pretty well dry. He said there was a leak, hole or tear in the seal between the back of the transmission and the front of the transfer case and all my tranny fliud was in the transfer case. He put in a quart and 1/2 of tranny fluid in just so something would show and said he has seen this quite a bit on the Fords. The transmission has always ...and still as I am writing this works flawlessly. Shifts smooth as silk and no issues at all in and out of 4 wheel drive.

Can anybody tell me what is going on?. I drove home the 53 miles from the oil change place with everything appearing to work, shift just fine

Thanks

 

Just got my tranny rebuilt last week or so, I noticed the same issue after I got the truck home and drove it for a day or two... The shop came and picked it up yesterday to fix it again. I will let you know what the exact cause of it was.

 

The seal between the TC and tranny needs to be replaced.

 

The transmission output shaft seal is leaking. Or someone over filled the t-case last go round.
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It was the double lip seal between the transfer case and transmission. The oil from the tranny was leaking into the transfer case. They tend to harden up but in my case the guy at AAmco said it looks like a faulty install indicating someone has been in there before. Jordanp, thats probably your issue.

total cost for transfer case removal install of new seal re install and all new fluids was 350 bucks.

 

That was part of my issue.... A a new output shaft seal to go along with it... Mine was covered by the shop that rebuilt my trans.. I told them it wasnt leaking like that before I brought it in and I sure and hell didnt cause it by driving it 25 miles.. So they covered the cost to fix it. I have another issue also, the truck would rev up before it dropped into 3rd gear. So they are fixing that also..