Scratching my head after transfer case fluid change...

[JonnyTahoe]

This is what I used and the book calls for. The Auto Trac II.

Last weekend I replaced my transfer case fluid. Done this many times on many 4x4's I have owned over the years. This time it's got me baffled, or I am just getting old and senile?

I cracked both the plugs loose.Then removed the drain plug. The old oil came out fast. When I removed the fill plug MORE oil came out of THAT hole! That freaked me out. Why the hell is it doing that??? Shouldn't it be coming out the bottom hole??

So I put the drain plug back in and started to fill it back up using a hand pump and hose. The book calls for 2 quarts. I pumped all 2 quarts in and still nothing came out of the fill hole, BUT when I removed the fill hose it must have been snug enough to block the damned hole so fluid started gushing the **** out.

So I am laying there on my back all ****** up and panicking with this brand new fluid running out all over the place and thinking should I let it keep doing that? Can it really be that over full if it is calling for 2 qts?? I mean I swear by the time I had to react I lost at least a half quart. I just jammed fill plug back in and snugged them up. Shit's got me a bit nervous....

I almost had that exact same thing happen to me when my trans pumped two more quarts into my Transfer case.

 

[89Suburban]

Oops double post.

 

[89Suburban]

Book recommends it because it's the OEM fluid.

Yes I understand that.

 

[jmm121783]

I had to also change my Transfer case and it was a total pain in the ass...A pressurized pump system wouldve saved me a ton of time and swearing LOL.

Anyway I went to home depot, picked up a brass flange that screwed into the top fill hole on the Tcase. Then I was using a smaller bottle and funnel with a hose running to the brass flange. It sucked, spilled probably a 1/2 qt as well and the biggest issue for me, THAT FLUID SMELL. OMG gear oil is absolutely the most DISGUSTING smell I have ever encountered when it comes to vehicle fluids, especially used gear oil.

Long story short, it was a huge mess and I got gear oil everywhere as well (I used BG Gear Oil that came in a 2 qt Black jug). When I was done filling I removed the brass flange and more oil started pouring out of the fill hole, mustve been slightly over filled but I also capped the drain as quick as possible. Seems like everything is good though as I had to use 4x4 HI the entire next day without an issue or any weird noises.

 

[JonnyTahoe]

I had to also change my Transfer case and it was a total pain in the ass...A pressurized pump system wouldve saved me a ton of time and swearing LOL.

Anyway I went to home depot, picked up a brass flange that screwed into the top fill hole on the Tcase. Then I was using a smaller bottle and funnel with a hose running to the brass flange. It sucked, spilled probably a 1/2 qt as well and the biggest issue for me, THAT FLUID SMELL. OMG gear oil is absolutely the most DISGUSTING smell I have ever encountered when it comes to vehicle fluids, especially used gear oil.

Long story short, it was a huge mess and I got gear oil everywhere as well (I used BG Gear Oil that came in a 2 qt Black jug). When I was done filling I removed the brass flange and more oil started pouring out of the fill hole, mustve been slightly over filled but I also capped the drain as quick as possible. Seems like everything is good though as I had to use 4x4 HI the entire next day without an issue or any weird noises.

Junk yards in the 80's use to have that nasty smell (its a chemical additive). Guys looking for Rear Diff's would open up the rear covers and just let the fluid drain out on the ground. Most of those yards have long since closed.

 

[George B]

The junk yards in the 80's use to have that awful smell(its a chemical additive). Guys looking for Rear Diff's would just open up the rear covers and let the fluid drain out on the ground. Most of those yards have long since closed.

Right! they reeked of gear lube!

 

[Fless]

I had to also change my Transfer case and it was a total pain in the ass...A pressurized pump system wouldve saved me a ton of time and swearing LOL.

Anyway I went to home depot, picked up a brass flange that screwed into the top fill hole on the Tcase. Then I was using a smaller bottle and funnel with a hose running to the brass flange. It sucked, spilled probably a 1/2 qt as well and the biggest issue for me, THAT FLUID SMELL. OMG gear oil is absolutely the most DISGUSTING smell I have ever encountered when it comes to vehicle fluids, especially used gear oil.

Long story short, it was a huge mess and I got gear oil everywhere as well (I used BG Gear Oil that came in a 2 qt Black jug). When I was done filling I removed the brass flange and more oil started pouring out of the fill hole, mustve been slightly over filled but I also capped the drain as quick as possible. Seems like everything is good though as I had to use 4x4 HI the entire next day without an issue or any weird noises.

Your transfer case uses gear oil?

 

[JonnyTahoe]

Your transfer case uses gear oil?

X2

 

[swathdiver]

gear oil is absolutely the most DISGUSTING smell I have ever encountered when it comes to vehicle fluids

Sound like my kids! LOL And I counter with what about the grape scent?!

You put gear oil in your 2009 SSVs transfer case? That unit should be a Magna 3023 and those take Dexron VI transmission fluid. RPO NQH.

 

[89Suburban]

Junk yards in the 80's use to have that nasty smell (its a chemical additive). Guys looking for Rear Diff's would open up the rear covers and just let the fluid drain out on the ground. Most of those yards have long since closed.

I use to work at one of those yards and I was the torch guy who had to cut frames and axles up into 2' pieces so they would fit in a scrap container better. You want to talk about stinky ass burning oil and black lung. And the burning rubber suspension bushings were just as bad.

 

[BigDogYJ]

I cracked both the plugs loose.Then removed the drain plug. The old oil came out fast. When I removed the fill plug MORE oil came out of THAT hole! That freaked me out. Why the hell is it doing that??? Shouldn't it be coming out the bottom hole??

to me this seems more than just an overfilled tcase? or leaking seal between trans and tacse, if thats possible. It seems something is keeping fluid separate from top to bottom? I have no idea how thats possible but what you explained has me trying to convince myself something between the top and bottom half of the tcase is plugged? This isnt an AWD case is it? I've never experienced that myself and I've serviced more than 15 different tcases. everyone I've done I always pull the fill plug first, if it pours out then I know theres either water or something else that overfilled it. but if you pull the drain plug first and it drains out, then you pull the fill AND it comes out the FILL plug?

Thats a new one. Sorry for not helping, just processing it out loud. I assume no strange noises and it operates normally? Im curious what would come out now if you pulled the drain plug, but dont want to you be wasting $$$ fluid.

 

[swathdiver]

I use to work at one of those yards and I was the torch guy who had to cut frames and axles up into 2' pieces so they would fit in a scrap container better. You want to talk about stinky ass burning oil and black lung. And the burning rubber suspension bushings were just as bad.

I love the smell of a junkyard in the morning! LOL

 

[wjburken]

everyone I've done I always pull the fill plug first

I always pull the full plug first as well, but I do it to make sure it’s not seized up. Nothing worse than draining the case and finding your fill plug won’t come out so you can put fluid back in.

Sorry for not helping, just processing it out loud.

So.....You talk while you type?

 

[89Suburban]

to me this seems more than just an overfilled tcase? or leaking seal between trans and tacse, if thats possible. It seems something is keeping fluid separate from top to bottom? I have no idea how thats possible but what you explained has me trying to convince myself something between the top and bottom half of the tcase is plugged? This isnt an AWD case is it? I've never experienced that myself and I've serviced more than 15 different tcases. everyone I've done I always pull the fill plug first, if it pours out then I know theres either water or something else that overfilled it. but if you pull the drain plug first and it drains out, then you pull the fill AND it comes out the FILL plug?

Thats a new one. Sorry for not helping, just processing it out loud. I assume no strange noises and it operates normally? Im curious what would come out now if you pulled the drain plug, but dont want to you be wasting $$$ fluid.

I appreciate your response. In my past experience I always cracked both plugs loose, took the drain plug out first, so it would not erupt. Then by the time I opened the fill plug, all was under semi-control. This is a new one to me.

 

[George B]

Is it hard to get the seal between the trans and transfer case out? I know you need to remove the case but how hard is it to get that seal out and a new one in?

 

[JonnyTahoe]

Is it hard to get the seal between the trans and transfer case out? I know you need to remove the case but how hard is it to get that seal out and a new one in?

.

 

[George B]

You mean the paper Gasket.

No, the oil seal that leaks and allows the trans fluid to migrate into the t-case.

 

[JonnyTahoe]

Is it hard to get the seal between the trans and transfer case out? I know you need to remove the case but how hard is it to get that seal out and a new one in?

You mean the paper Gasket.

No, the oil seal that leaks and allows the trans fluid to migrate into the t-case.

 

[JonnyTahoe]

No, the oil seal that leaks and allows the trans fluid to migrate into the t-case.

Never replaced one.

 

[jmm121783]

Sorry for not being PC lol....hopefully my buddy working at the dealership gave me the right shit, everything is working well....

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