How To: Transfer Case Fluid Change (Photo thread) - Ford Explorer Ranger Enthusiasts "Serious Explorations"®

ExplorerDMB · 02-15-2006, 06:37 PM

I decided to change my transfer case fluid since I just went over 77K recently. I don't really know the intervals - but you should check it once you get around 60K. The fluid is just normal Dexron Mercon III ATF- so if you know what burnt transmission fluid looks like and smells like - you know what to look for in your tcase if it needs to be changed. My transfercase is the 4405 Borg-Warner T-case.

The service itself is quiet easy: all you need is a 3/8s raceht, a funnel or pump, drain bucket, and your choice of fluid (3 pints or about 2 quarts worth).

I did this at my house instead of the shop, so I was limited to a funnel which is kind of tricky to use on a transfercase. Anyhow, first you need to find the drain and fill plugs. I recommend removing the fill plug first to allow air to get into the t-case which will allow the fluid to run out of the drain smoother instead of in "gulps" (people who have done this before know what I mean). Anyhow here's a picture for help:

Drain and Fill Plugs:

Undoing the Fill/Check Plug:

Once you have taken the fill plug out, go ahead and set that aside and get going on the drain plug. Both plugs should be pretty tight (mine had thread sealer on them previously), but putting the plugs back should only be snugged like a oil drain plug. When you are ready to pull the drain plug on the t-case, thread it out with your fingers and set your drain pan underneath it. This should catch all the fluid and you should just let it drip out.

Undoing the drain plug:

Fluid Running Out:

Once it is emptied as good as it's going to get, put the drain plug back in. I like to clean up the area with brake clean, so if for some reason I get a leak, I can pinpoint it easier. Now, time to fill 'er up:

How My Funnel Was:

It worked out quiet well with my driveshaft there. Anyhow, gently fill it up and fill it like a differential - until it starts to flow out of the fill hole. Once it gets the big gushes out and its just lightly letting out - go ahead and put the plug back. Make sure you tighten it:

That's it! You're done. I put Royal Purple synthetic ATF fluid in my transfer case. I am running royal purple in my differentials and t-case now. I am still in search for a Mercon V fully-synthetic fluid (I believe just Amsoil has it right now). Picture of the bottles are below. Hope this was easy enough for you - was pretty easy to me!

Good luck

-Drew

**Glacier991** · 02-15-2006, 09:24 PM

Another excellent thread Drew. Thanks.

*'97 V8* · 02-15-2006, 09:43 PM

looks easy. i need to change the t-case oil too.

*SkanlaxJMO* · 02-15-2006, 10:18 PM

look's "easy" with my luck the drain plug and the fill plug will be frozen on...lol

*'97 V8* · 02-15-2006, 10:23 PM

haha, true true. you know how it is.

pgdsm · 04-01-2006, 07:06 PM

Quote:

Originally Posted by '97 V8

looks easy. i need to change the t-case oil too.

why dont we get to gether and both do this??

*dkchrist* · 10-04-2006, 12:37 AM

good write up might oughta check mine @ 50k now

wmorrisw · 03-18-2007, 12:14 PM

my transfer case is leaking. Can the tranfer case cover be removed on the car?
I have 98 4x4 Explorer 4.1 sohc.

ExplorerDMB · 03-18-2007, 01:18 PM

if transfer case service is needed - I would recommend removing the whole transfer case and working on it on a bench

-Drew

wmorrisw · 03-18-2007, 04:47 PM

The cover just seems to be leaking a little. Can it come off without removing the whole thing?

ExplorerDMB · 03-18-2007, 06:22 PM

It's like 6 bolts holding the transfercase to the trans. The cover has like 12-15 bolts. I think it might be hard to remove the cover still attatched to the trans due to room.

-Drew

**Glacier991** · 03-18-2007, 09:51 PM

As a part of the 4405 Rebuild Diary,(a shameless plug for you to go read it,) I did find that Mobil 1 now is openly claiming Merc V compatability on the bottle.

tktrain · 03-19-2007, 11:42 AM

I switched over to Mobil 1 ATF in my X about 3 months ago. It is indeed Mercon V rated.

sport01mi · 05-03-2007, 06:04 PM

Sounds like you just saved me 20 dollars. :-) Thank-you!

X-North · 08-06-2007, 11:32 PM

frozen plug...thats why you need some lube and a straight bar :P if you dont have it then a ratchet and a piece of 2 feet long pipe would do the job

g8r · 08-07-2007, 11:07 PM

Okay stupid question.......is just jacking up the front end good enough?

X-North · 08-07-2007, 11:28 PM

Quote:

Originally Posted by g8r

Okay stupid question.......is just jacking up the front end good enough?

Yes ...even not jacked you can do the oil change ...but if its stuck there you gonna says some bad words heheheh

X-North · 08-24-2007, 07:25 AM

Thank you for it mister but I have a kind of damper in front of my drain hole....do you have any idea how to revome that damper ??? BTW the sell pump at wal mart for around 20 bucks now...you can use it both on air and liquid...i have found it on the wall near oil racks and sports center...so somewhere between the car oil and the ATV oil :P

shortstack · 10-25-2007, 02:52 AM

do you guys think synthetic will make any difference in the transfer case?

**IZwack** · 10-25-2007, 03:00 AM

I think for you, living in Alaska, it would be worthwhile to go with synthetics because synthetics are affected less by temperature than conventional oil.

02-15-2006, 06:37 PM	#1
ExplorerDMB Moderator/Technician Mechanicsville, Virginia 2004 Acura TL Join Date: Jan 2004 Posts: 6,267 Vehicle Specs	How To: Transfer Case Fluid Change (Photo thread) I decided to change my transfer case fluid since I just went over 77K recently. I don't really know the intervals - but you should check it once you get around 60K. The fluid is just normal Dexron Mercon III ATF- so if you know what burnt transmission fluid looks like and smells like - you know what to look for in your tcase if it needs to be changed. My transfercase is the 4405 Borg-Warner T-case. The service itself is quiet easy: all you need is a 3/8s raceht, a funnel or pump, drain bucket, and your choice of fluid (3 pints or about 2 quarts worth). I did this at my house instead of the shop, so I was limited to a funnel which is kind of tricky to use on a transfercase. Anyhow, first you need to find the drain and fill plugs. I recommend removing the fill plug first to allow air to get into the t-case which will allow the fluid to run out of the drain smoother instead of in "gulps" (people who have done this before know what I mean). Anyhow here's a picture for help: Drain and Fill Plugs: Undoing the Fill/Check Plug: Once you have taken the fill plug out, go ahead and set that aside and get going on the drain plug. Both plugs should be pretty tight (mine had thread sealer on them previously), but putting the plugs back should only be snugged like a oil drain plug. When you are ready to pull the drain plug on the t-case, thread it out with your fingers and set your drain pan underneath it. This should catch all the fluid and you should just let it drip out. Undoing the drain plug: Fluid Running Out: Once it is emptied as good as it's going to get, put the drain plug back in. I like to clean up the area with brake clean, so if for some reason I get a leak, I can pinpoint it easier. Now, time to fill 'er up: How My Funnel Was: It worked out quiet well with my driveshaft there. Anyhow, gently fill it up and fill it like a differential - until it starts to flow out of the fill hole. Once it gets the big gushes out and its just lightly letting out - go ahead and put the plug back. Make sure you tighten it: That's it! You're done. I put Royal Purple synthetic ATF fluid in my transfer case. I am running royal purple in my differentials and t-case now. I am still in search for a Mercon V fully-synthetic fluid (I believe just Amsoil has it right now). Picture of the bottles are below. Hope this was easy enough for you - was pretty easy to me! Good luck -Drew Attached Images __________________ My Useful Threads (38 Entries and Growing)

02-15-2006, 09:43 PM	#3
'97 V8 Elite Mountaineer Lima, Ohio '97 mounty 5.0 4x4 baby!! Join Date: Apr 2005 Posts: 3,698 Vehicle Specs	looks easy. i need to change the t-case oil too. __________________ 1997 Mercury Mountaineer 4x4 V8 3" bl, manual t-case. Dana 60/14 bolt combo with 36x13.5x17 iroks on H2 rims. 5.13's. Future plan: 3.9 or 5.9 Turbo diesel cummins

02-15-2006, 10:18 PM	#4
SkanlaxJMO Elite Explorer Syracuse, New York 96 XLT Join Date: Sep 2005 Posts: 3,138 Vehicle Specs	look's "easy" with my luck the drain plug and the fill plug will be frozen on...lol __________________ 96' XLT 4wd My Explorer What Tony has to say about me and my truck Thats your firstborn child we all know your kids are gonna have to fight for attention with you and your fords.

02-15-2006, 10:23 PM	#5
'97 V8 Elite Mountaineer Lima, Ohio '97 mounty 5.0 4x4 baby!! Join Date: Apr 2005 Posts: 3,698 Vehicle Specs	haha, true true. you know how it is. __________________ 1997 Mercury Mountaineer 4x4 V8 3" bl, manual t-case. Dana 60/14 bolt combo with 36x13.5x17 iroks on H2 rims. 5.13's. Future plan: 3.9 or 5.9 Turbo diesel cummins

03-18-2007, 12:14 PM	#8
wmorrisw Wannabe Elite Explorer SCHAUMBURG, IL 1998 EXPLORER SPORT Join Date: Aug 2006 Posts: 16 Vehicle Specs	my transfer case is leaking my transfer case is leaking. Can the tranfer case cover be removed on the car? I have 98 4x4 Explorer 4.1 sohc.

02-15-2006, 09:24 PM	#2
Glacier991 EF Tranny Guru Sacramento, CA 95827 1992 XLT Join Date: Feb 2003 Posts: 9,779 Vehicle Specs	Another excellent thread Drew. Thanks.

10-04-2006, 12:37 AM	#7
dkchrist I am here...I think Ellsworth, KS '03 Ranger XLT 4x4 Join Date: Aug 2006 Posts: 1,035 Vehicle Specs	good write up might oughta check mine @ 50k now

03-18-2007, 01:18 PM	#9
ExplorerDMB Moderator/Technician Mechanicsville, Virginia 2004 Acura TL Join Date: Jan 2004 Posts: 6,267 Vehicle Specs	if transfer case service is needed - I would recommend removing the whole transfer case and working on it on a bench -Drew __________________ My Useful Threads (38 Entries and Growing)

03-18-2007, 04:47 PM	#10
wmorrisw Wannabe Elite Explorer SCHAUMBURG, IL 1998 EXPLORER SPORT Join Date: Aug 2006 Posts: 16 Vehicle Specs	The cover just seems to be leaking a little. Can it come off without removing the whole thing?

03-18-2007, 06:22 PM	#11
ExplorerDMB Moderator/Technician Mechanicsville, Virginia 2004 Acura TL Join Date: Jan 2004 Posts: 6,267 Vehicle Specs	It's like 6 bolts holding the transfercase to the trans. The cover has like 12-15 bolts. I think it might be hard to remove the cover still attatched to the trans due to room. -Drew __________________ My Useful Threads (38 Entries and Growing)

03-18-2007, 09:51 PM	#12
Glacier991 EF Tranny Guru Sacramento, CA 95827 1992 XLT Join Date: Feb 2003 Posts: 9,779 Vehicle Specs	As a part of the 4405 Rebuild Diary,(a shameless plug for you to go read it,) I did find that Mobil 1 now is openly claiming Merc V compatability on the bottle.

03-19-2007, 11:42 AM	#13
tktrain Wannabe Elite Explorer Evansville, IN '98 XLT 5.0 Join Date: Aug 2004 Posts: 114 Vehicle Specs	I switched over to Mobil 1 ATF in my X about 3 months ago. It is indeed Mercon V rated. __________________ 1998 5.0 XLT AWD, Pacific Green Clearcoat Metallic, 17x9 Cobra R rims, 275/55R17 General Grabber ST's E303 cam and springs/retainers, FMS Headers, 3" custom catback, 1.7:1 Crane/Cobra roller rockers, FMS phenolic 1" spacer, Accel coil packs, Taylor wires, K&N, B&M shift plus

05-03-2007, 06:04 PM	#14
sport01mi Wannabe Elite Explorer Woodhaven, MI 01 Sport Join Date: Jun 2005 Posts: 71 Vehicle Specs	Sounds like you just saved me 20 dollars. :-) Thank-you!

08-06-2007, 11:32 PM	#15
X-North Wannabe Elite Explorer Montreal Join Date: Jul 2007 Posts: 555 Vehicle Specs	frozen plug...thats why you need some lube and a straight bar :P if you dont have it then a ratchet and a piece of 2 feet long pipe would do the job

08-07-2007, 11:07 PM	#16
g8r Wannabe Elite Explorer Burlington, Ontario 95 Join Date: Dec 2003 Posts: 115 Vehicle Specs	Okay stupid question.......is just jacking up the front end good enough?

08-24-2007, 07:25 AM	#18
X-North Wannabe Elite Explorer Montreal Join Date: Jul 2007 Posts: 555 Vehicle Specs	Thank you for it mister but I have a kind of damper in front of my drain hole....do you have any idea how to revome that damper ??? BTW the sell pump at wal mart for around 20 bucks now...you can use it both on air and liquid...i have found it on the wall near oil racks and sports center...so somewhere between the car oil and the ATV oil :P

10-25-2007, 02:52 AM	#19
shortstack Wannabe Elite Explorer Alaska 1998 Eddie Bauer 4.0L Join Date: Jul 2007 Posts: 792 Vehicle Specs	do you guys think synthetic will make any difference in the transfer case? __________________ Oil Drain Plug Mod LED Parking Light Rack Homemade Heat Shield-Air Intake Vortex Muffler from Cherry Bomb, Video 3 Watt LED Puddle Lamps homemade 3 Watt LED Cargo Light homemade

10-25-2007, 03:00 AM	#20
IZwack Germantown, MD Join Date: Feb 2003 Posts: 17,752 Vehicle Specs	I think for you, living in Alaska, it would be worthwhile to go with synthetics because synthetics are affected less by temperature than conventional oil. __________________ »»»»» Exsqueeze me? Baking powder?