Was changing the fluid in the BW-4406 transfer case (99 F-150 5.4) and I have a funnel with a hose on the end. The tip of the hose had a plastic insert and it fell inside the transfer case. It's maybe 3/8" diameter x 2" long and made of plastic. I tried getting a piece of copper wire and fishing around until I might be able to see something at the drain port, but was unable to find it.

I was advised it would likely just fall to the bottom of the TC and stay there, so I buttoned it back up, filled it with fluid and went for a road test. All seems fine.

I'm worried it might somehow get caught in the chain and bugger things up. I was thinking of driving for a bit and maybe doing another fluid change later to see if it comes out then. Thoughts / advice?

 

I did the same thing when I did a trans oil change on my F350 6-speed manual trans. The tech told me to leave it, the trans will turn it into harmless pieces. I guess it did, never had a problem.

 

I'd say the transfer case will easily win when the fight ensues