T-case burning ATF

[Jefe]

A while ago, at 30k miles, I changed my t-case fluid, just to be safe (the manual doesn't say anything until 120k I beleive). Well, its sopposed to be ATF fluid, but it was black. At the time I assumed that jiffy-lube or someone else (I bought the Ex used at 19k miles) had just topped it off with gear oil instead of ATF, not knowing any better.

I'm now at 43k miles and a few days ago i start to notice that my auto 4x4 is starting to engage and disengage very rough, and seems to be putting too much power up front. I was at Jiffy lube today, so I told them to check the T-case. Its full, but its black again! So i have them change it out, and now it drives fine again.

I know only ATF has been put in since 30k because I watch Jiffy lube do it every time. So why is my T-case burning (?) ATF?

 

[Rick]

My manual transmission also uses ATF and the fluid turns black in short order. I now change the fluid in the tranny twice a year regardless of mileage. I don't remember my transfercase ever turning the fluid black though.

I know you guys have a clutch in your T-case, but I have never seen a diagram of it and therefore I don't know how it works. If there are clutch discs like in an auto tranny they could be slipping causing the fluid to blacken.

 

[Jason_25]

How about your 4-high and 4-low? Are they working ok?

 

[Jefe]

4x4 auto, hi and low work.
only time i had a problem, I was rock crawling and had gotten both rear tires off the ground, because of rocks under the frame, and then the t-case made a clicking/clunking sound (like when it releives drivetrain windup, but not so loud) and my front tires weren't spinning. I figured that my front tires were having to do so much work that the t-case couldn't handle it.

Has anyone had to have their T-case rebuilt?

. . .or maybe its just time for an Atlas II. .

 

[Rick]

Didn't Gerald just have to replace or rebuild his??

 

[Jason_25]

Jefe, Ford recommends that the TC's do not be rebuilt. They are "one time use only" LOL. You could always go with a manual BW1354 like I am using, it's a lot cheaper than an Atlas, I can;t afford one.

My (novice) answer to your question is that particulate matter in your TC from the cluthes is floating around inside and combines with the new fluid you put it in and makes it dark.

 

[Jefe]

Ok, yes the ATF doesn't smell burnt. . .so its just that I'm wearing down my clutch(es) rather quickly?

Meaning that at some [life threatening] time while off-roading my t-case is going to cease to work?

 

[Jason_25]

Yes.....probably. See, you rarely see 2nd Gen Explorer guys complaining about their t-case. In fact, the only people who I know of have said there was something wrong were you and Gerald. Fact of the matter probably is: you wheel too hard for a transfer case designed for the grocery store.

 

[Jefe]

Originally posted by Jason_25
...you wheel too hard for a transfer case designed for the grocery store.

LOL. . .Thats an understatement if I've ever heard one. . .

 

[Jefe]

I figure I'll post a follow-up to this.

After I posted this I continued with the assumption that I wheeled too hard. I started changing T-case fluid every 1500 mi to prolong the clutch life (even after that short length it would still be darker than it should have been)

Time passes and I get 4.88's (from 4.10's) installed to help out my 35's. My 4WD lights start to flash, indicating a problem with the Auto 4x4 system. Traced it down to a speed sensor problem. Replaced both speed sensors. Still no luck.

I was hoping that the regearing was going to somewhat correct my speedo (It was still set for stock tires/gears) and It didn't so I was a little confused. . and then found out that 98+ get their speed from the ABS module. So I bought a Superlift TrueSpeed to adjust my speedo.

As soon as my speedo was adjusted the 4wd lights went away, and even better, the slight binding that I thought was normal in Auto 4x4 was gone.

So the true problem was that the T-case speed sensors and the ABS speed sensors were not matching, making the Auto 4x4 bind, causing excesive wear.

However I found the problem too late. Occasionally when it engages the front shaft now it sounds like metal on metal, so I think I've completely worn the cluch out.

So I was forced to call Advanced Adapters and order an Atlas II

 

[DesertSpive]

It is okay to be dark!

The Mercon III (I believe) that the t-case and trans has will turn color at a low temp. I was talking to a Ford tech about this. When I changed my tranny and t-case to Mobil-1 ATF at 7000 miles, my fluids came out dark, but didn't smell burnt. I come to find out that there is a service bulliten on this. Apparently the Mercon III turns dark at something like 89 degrees. When it first came out, people thought something was wrong and Ford issued a Bulliten saying that it was normal. Hope this helps...

--Sean

 

[Jefe]

No I wouldn't be worried about it being a little dark. . but Its always black, sometimes with visible chunks

 

[Blake D]

Ummmm what about a 94? I just replaced all my fluids and I was told that the tcase would use the same a s the diffs. I used moble 1 synthetic but will this hurt my tcase? If so how soon should I replace the fluid or is it ok in my 94?

 

[SteveVB]

Replace it now!!

The 94 TC has a pump in it and I doubt it is up to the task of pumping 75w gear oil(the axles lube), all of the explorer transfer cases use ATF.

I would replace it now. Use ATF in the transfer case.

Good Luck

 

[Blake D]

Thanks! Oh great that means I just blew the $ for the Mobil 1. That was expensive! Will it last till the end of the week? I only drive 8 miles to and from work and that is about all it gets driven. Could I have seriously damaged it already? I haven;t had any problems yet but what could this have done?
Thanks again!
Blake

 

[addkev]

Ummmm what about a 94? I just replaced all my fluids and I was told that the tcase would use the same a s the diffs. I used moble 1 synthetic but will this hurt my tcase? If so how soon should I replace the fluid or is it ok in my 94?

Ouch that is not good. Do not wait until friday.

I agree with DesertSpive, I don't know what it is with Mercon III, but it always turns dark fast. I just replace mine every 20k/12 months whether it needs it or not.

 

[Blake D]

Al what could I have hurt? If I drain it and put in the Mercron will I be ok or do I need to do something to flush the old stuff out?

 

[DesertSpive]

I removd the Ford fuid and am running Mobil ATF in my t-case and tranny. ('02 Ranger)

--Sean