Transfer case and diff'l fluid change

[BHMTitan]

I did my 30K fluid changes yesterday. When I opened the "fill" plug on the front diff, the fluid was low; couldn't touch it w/ my pinky. When drained, the old fluid was really dark. When I drained the rear diff, the fluid was no where near as dark as the front.

Today, checking everything again for any leaks, I found oil underneath the frame near the front left tire. I checked the front diff and everything was dry around the plugs. I then checked the front diff overflow, behind the breather box, and that was the source.

I only filled the front until it barely started running back out... so don't believe it's overfilled. You guys think the overflow, along with the low / dark color of the previous fluid is cause for a trip to the dealer to have things checked out? I'm still under warranty.

Thanks....

[VA06TITAN]

Originally Posted by BHMTitan

I did my 30K fluid changes yesterday. When I opened the "fill" plug on the front diff, the fluid was low; couldn't touch it w/ my pinky. When drained, the old fluid was really dark. When I drained the rear diff, the fluid was no where near as dark as the front.

Today, checking everything again for any leaks, I found oil underneath the frame near the front left tire. I checked the front diff and everything was dry around the plugs. I then checked the front diff overflow, behind the breather box, and that was the source.

I only filled the front until it barely started running back out... so don't believe it's overfilled. You guys think the overflow, along with the low / dark color of the previous fluid is cause for a trip to the dealer to have things checked out? I'm still under warranty.

Thanks....

How many quarts did you use for the front diff? you should have only used just under 2 quarts (1.7 quarts to be exact).

[BHMTitan]

Originally Posted by VA06TITAN

How many quarts did you use for the front diff? you should have only used just under 2 quarts (1.7 quarts to be exact).

I didn't measure it, just filled until it barely started running back out. I had a little less that half of a qt remaining in the 2nd bottle when finished, so 1.7 qt in is about what I did.

[jmacougar]

Originally Posted by HRTKD

I'm going to go out on a very short limb here and say that there is no filter in the transfer case. I have not heard of having a filter in a transfer case before and I don't recall seeing anything close to a transfer case pan where a filter would be serviced from.

As I recall I used the RTV on the drain plug. No problems yet. I might go with teflon tape next time since it is a lot cleaner and easier to use..

The above reply and a few others like are a few months old ... but in response to it. And for those of you that would like to know ... like myself ... there is indeed an oil filter on the transfer case at least on the '04's. I used to have an '04 ... but now have an '05. The '05 does not have one. Nonetheless ... here are the directions per the '04 Service Manual:

Page 1, Page 2

Also make note ... it says to REPLACE the three o-rings.

The above has been omitted from later revisions of the service manual.

Although I have the manual ... and have read thread after thread ... I can't seem to figure out what kind of tool I'm supposed to use to remove the t-case drain/fill plugs ... can someone please enlighten me ... PLEEEZE!

Also ... I found out the hard way when I was performing my 30K service today. I started with the front ... easy as pie. The rear ... I pulled the drain plug and maybe .25 of a quart drained out. I was like OH CRAP ... I've had no fluid for who knows how long!!!! And I've been pulling a 6000 lb boat and trailer!!! But it didn't look black ... so I was REALLY confused.

When I started to fill it back up ... I didn't even get half the bottle put in before it started overflowing ... then I was like WTF!!! I was pretty pissed off. I figured there must have been an air pocket or something that kept the oil from draining. I pull the plug again and a ton of oil pours out and there is another huge mound of sludge on the plug. So I guess it was REALLY clogged up. Fortunately I purchased enough oil to finish the job.

What's the lesson? If little to nothing comes out or even when the flow seems to be done ... make sure you stick a screwdriver or something in the drain hole before you put everything back together and then spill a bunch of your brand new expensive oil all over the concrete. That goes for the front too.

Now that I've hopefully helped someone out there ... please let me know what tool I need to use to get those plugs out of the t-case and where I can get one.

Thanks,

Jason

[Blackbeauty]

Originally Posted by jmacougar

The above reply and a few others like are a few months old ... but in response to it. And for those of you that would like to know ... like myself ... there is indeed an oil filter on the transfer case. Here are the directions per the Service Manual:

Page 1, Page 2

Also make note ... it says to REPLACE the three o-rings.

Although I have the manual ... and have read thread after thread ... I can't seem to figure out what kind of tool I'm supposed to use to remove the t-case drain/fill plugs ... can someone please enlighten me ... PLEEEZE!

Also ... I found out the hard way when I was performing my 30K service today. I started with the front ... easy as pie. The rear ... I pulled the drain plug and maybe .25 of a quart drained out. I was like OH CRAP ... I've had no fluid for who knows how long!!!! And I've been pulling a 6000 lb boat and trailer!!! But it didn't look black ... so I was REALLY confused.

When I started to fill it back up ... I didn't even get half the bottle put in before it started overflowing ... then I was like WTF!!! I was pretty pissed off. I figured there must have been an air pocket or something that kept the oil from draining. I pull the plug again and a ton of oil pours out and there is another huge mound of sludge on the plug. So I guess it was REALLY clogged up. Fortunately I purchased enough oil to finish the job.

What's the lesson? If little to nothing comes out or even when the flow seems to be done ... make sure you stick a screwdriver or something in the drain hole before you put everything back together and then spill a bunch of your brand new expensive oil all over the concrete. That goes for the front too.

Now that I've hopefully helped someone out there ... please let me know what tool I need to use to get those plugs out of the t-case and where I can get one.

Thanks,

Jason

If I'm not mistaken, all you need is the end of a 3/8" ratchet..... or you can put a short extension on your ratchet and that will work, too. No special tool required.

[jmacougar]

Hey all ... never mind about my question. I think I was a little too stressed out yesterday and not thinking clearly. After sleeping on it ... it dawned on me that it needs a hex-head (Allen wrench). Which I have plenty of ... I've just never seen one quite that large ... so it threw me off. It's 10mm to be exact ... my largest ... got lucky there. But I still feel stupid for asking the question. DOH! But at least there's more info on the how-to in this thread than any other thread I've found. Here's an overall run-down of what you need to do all three components:

Front Differential

• 3/8" ratchet extension ... goes right into the plugs as if they were sockets
• 75W-90 gear oil ... just over 2 quarts ... preferrably Amsoil or Royal Purple. I used RP this time ... but will probably get Amsoil next time. I was in a rush to get it done and didn't have time to order/wait.
• Pump ... can be found right next to the gear oil. Looks like a pump for a soap dispenser and makes the job SUPER EASY for 4 bucks!
• Permatex High-temp Thread sealer for the plugs
• Torque Wrench - 20 lb for the bottom and 25 lb for the top

Rear Differential ... everything is the same as front ... except:

• 75W-140 gear oil ... just under 2 quarts
• 20 lb for both top and bottom plugs

Transfer Case:

• 10 mm hex-head (Allen wrench)
• New gaskets ... other people reuse them w/o problems. My luck ... they'd leak. So I'm replacing them.
• A second pump because you don't want to mix the gear oil with the transmission fluid.
• ATF fluid ... just over 2 qts ... I used Royal Purple Max ATF. Again ... I'm going to use Amsoil next time when I have more time.
• Both plugs are tightened to 26 lb ... and don't use the Permatex on these plugs.

If you have a t-case oil filter: My '05 does not have one. I used to have an '04 and don't know if had one or not. The following is from the '04 Service Manual. It has been omitted from later versions.

• New t-case oil filter ... and 3 new o-rings. (Page 1, Page 2). I would assume everything comes together in a set.

I think this needs to made into a sticky or something.

Jason

[Blackbeauty]

Ooppp! You're right.. Allen wrench... My bad.