99 Mounty Transfer case? What model?

[hsinc]

Have a 99 V8 Mounty, AWD, which I have been plagued with transfer case problems. I've mentioned on this thread before. The problem is that the seal between the transmission and transfer case, allows transmission fluid from the transmission to leak into the transfer case. I pulled the fill plug on the transfer case last night, and again I had about 1 1/2 quarts of fluid come out. I thought the problem had been fixed about 6 monthes ago, by replacing the seal. But obviously something else is wrong. Perhaps worn bearing, allowing the transmission shaft to wobble, causing the seal to not function properly?? I don't know.
Any ideas out there? What happens is that my transmission ends up low on fluid when this happens.
I looked at the tag on my transfer case and the first 4 numbers are 4404, Borg Warner. Some drive train websites list 4403, some list 4404 for the 99 models. Is 4404 the correct model for the 99AWD? I don't have any vibration, but I do have a whiny noise on acceleration or going up hill. On previous posts, everyone has told me this is normal on the Ford AWD. But somehow I don't think it is.
Curious if anyone else has problem with this fluid loss into transfer case, and what they did to fix it.
Thanks,
Harold

 

[97BlackX5.0]

okay ive taken apart a 97 model which is almost identical to yours ... in order for your transfer case to fill up with fluid the input shaft seal would have to be bad.... if you look up under the truck youll see the tranny and then the adapter housing and then the transfer case. now the tranny will allow the extension housing to get some fluid in it but ive never heard of it filling up..... i would say pull the transfer case and replace seals in it if its filling up... its not terribly hard to get it out... just requires a torch and some stretchy arms to reach around and undo the 8 bolts that hold the tcase to the tranny... then u heat up the driveshaft bolts to melt the thread lock and its basically slides off.... i dunno im still having a hard time believing that it is filling up the transfer case above and beyond what it should be all on its own.... sounds weird to me

 

[Mbrooks420]

The BW4404 is the t-case under your truck.

 

[hsinc]

Thanks for the answers so far. Yea it fills up with trans fluid. My transmission is low and my transfer case is very full. Like I say this is twice now. The first time I had the front seal replaced by Mr. Transmission. I had them save me the old seal, and in all honesty, it did not look particularly worn. Now it has happened again. I am thinking I must have a bad bearing, allowing excess wobble. I may order seals and bearings online and try this repair soon. Just curious if anyone else has had same problem.
Harold