Now the transfer case GRRRRRRR!

[RyanZ71]

Got the front diff done, now working on the transfer case oil. I took out the drain plug and got maybe half a cup if even that of the oil that came out! What the heck!? I'm in a little bit of a panic now because if there was more that needed to come out which I would think there would be if it calls for 2 quarts of the stuff when putting it in, then something bad has happend! Also when I removed the drain plug I found a bit of thin black gasket material, maybe an inch and a half long that I pulled out of the drain plug port. Any ideas?

[snoman]

Got the front diff done, now working on the transfer case oil.  I took out the drain plug and got maybe half a cup if even that of the oil that came out!  What the heck!?  I'm in a little bit of a panic now because if there was more that needed to come out which I would think there would be if it calls for 2 quarts of the stuff when putting it in, then something bad has happend!  Also when I removed the drain plug I found a bit of thin black gasket material, maybe an inch and a half long that I pulled out of the drain plug port.  Any ideas?

 

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It is not too unusual to find peice of black RTV inside of case (it is not harmfull and that is why they use it) but the low oil level suggest that it has a leak somewhere or was never filled properly but I tend to go with the leak. If you are lucky, no damage has been done yet. Time will tell.

[RyanZ71]

thanks for the reply snoman. Here is what I found:

 

I went ahead and put in just about 2 quarts of the GM blue transfer case fluid. It says in the tech article to fill it up all the way until the stuff comes out of the fill port which is what I did. I then drove the truck around for a bit cycling it in 4wd and 2wd a few times while driving, returned to my house and looked under and noted some blue fluid SLOWLY dripping from the drain port. I have a feeling that the drain bolt and probably the fill bolt are not really sealing all that well, its just metal to metal. The dealers around here don't have any of the bolts in stock, will take a few days to get them in but at least I know whats happening now. I just hope and pray no severe damage was done to the transfer case otherwise I'm guessing I'll be paying over $800+ to have a new one installed. I'll look at it this way when the new bolts come in, Its a great transfer case system flush when I have to re-fill the sucker after putting the new bolts in! I'm going to tackle the rear diff next month but the front diff and transfer case is done, wasn't all that hard other then the panicy moments. I strongly suggest that those who decide to do these items on their own get a hand pump that will fit over the oil bottles. You can purchase them from any decent auto parts store. By changing the fluid out myself, I probably save over $200 worth of service and only paid about $40.00 for the parts from GM and the auto parts store. The tech articles on this website came in very handy.

[dougs01gt]

thanks for the reply snoman.  Here is what I found:

 

I went ahead and put in just about 2 quarts of the GM blue transfer case fluid.  It says in the tech article to fill it up all the way until the stuff comes out of the fill port which is what I did.  I then drove the truck around for a bit cycling it in 4wd and 2wd a few times while driving, returned to my house and looked under and noted some blue fluid SLOWLY dripping from the drain port.  I have a feeling that the drain bolt and probably the fill bolt are not really sealing all that well, its just metal to metal.  The dealers around here don't have any of the bolts in stock, will take a few days to get them in but at least I know whats happening now.  I just hope and pray no severe damage was done to the transfer case otherwise I'm guessing I'll be paying over $800+ to have a new one installed.  I'll look at it this way when the new bolts come in, Its a great transfer case system flush when I have to re-fill the sucker after putting the new bolts in!  I'm going to tackle the rear diff next month but the front diff and transfer case is done, wasn't all that hard other then the panicy moments.  I strongly suggest that those who decide to do these items on their own get a hand pump that will fit over the oil bottles.  You can purchase them from any decent auto parts store.  By changing the fluid out myself, I probably save over $200 worth of service and only paid about $40.00 for the parts from GM and the auto parts store.  The tech articles on this website came in very handy.

 

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Did you put some teflon tape on the threads?? This might help with leaks.

[snoman]

thanks for the reply snoman.  Here is what I found:

 

I went ahead and put in just about 2 quarts of the GM blue transfer case fluid.  It says in the tech article to fill it up all the way until the stuff comes out of the fill port which is what I did.  I then drove the truck around for a bit cycling it in 4wd and 2wd a few times while driving, returned to my house and looked under and noted some blue fluid SLOWLY dripping from the drain port.  I have a feeling that the drain bolt and probably the fill bolt are not really sealing all that well, its just metal to metal.  The dealers around here don't have any of the bolts in stock, will take a few days to get them in but at least I know whats happening now.  I just hope and pray no severe damage was done to the transfer case otherwise I'm guessing I'll be paying over $800+ to have a new one installed.  I'll look at it this way when the new bolts come in, Its a great transfer case system flush when I have to re-fill the sucker after putting the new bolts in!  I'm going to tackle the rear diff next month but the front diff and transfer case is done, wasn't all that hard other then the panicy moments.  I strongly suggest that those who decide to do these items on their own get a hand pump that will fit over the oil bottles.  You can purchase them from any decent auto parts store.  By changing the fluid out myself, I probably save over $200 worth of service and only paid about $40.00 for the parts from GM and the auto parts store.  The tech articles on this website came in very handy.

 

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Did you put some teflon tape on the threads?? This might help with leaks.

 

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Not a bad idea but usually if you snug the steel pipe threaded bolt in the softer aluminum case snug enough it will stop leaking. For filling I use a piece of fuel line hose on the cut of nipple for a gear oil qt bottle to put oil in and have done so for years with good success. I suppose I could get a pump but never did.

[Guest 007FL]

It can't hurt to take a sample of the fluid you just put in (after a few hundred miles) and send it in for analysis. Might tell you if there is anything going on.

[Burrito]

I had a transfer case issue with my 2001 2500 HD. I was getting a vibration and a bad clunk in the drivetrain. Took it to my tranny shop and they found that there was only about 1/2 cup of fluid in it. Needless to say, it was ruined. Kinda like only having 1 quart of oil in your crankcase when it calls for 5. They said there was a crack or a leak of somekind on the top of the case. It only lost fluid when the vehicle was running and their was pressure to push the fluid out of the top. The slip yoke was all messed up too. They ordered me a new transfer case and nickel plated slip yoke and now I'm good to go. (With $2100 less in my pocket)

 

I hope this is not the problem with yours. Now that you've noticed a problem, check your fluid often to make sure your not leaking fluid like I was.

[RyanZ71]

<sigh> I kinda have a feeling the damage has been done. Life really sucks sometimes. I'm going to keep driving her until something happens but already noticing a little slippage when taking off from a stop, not the clunk that I'm used to from the crappy slip yoke. I'm going to drain and refill the fluid this weekend or next weekend since I've driven it around a bit and see what the fluid looks like again. Folks, make sure you check the levels in your differential and transfer case!!! Only 93,000 miles on my truck and look what happend!

 

 

 

I had a transfer case issue with my 2001 2500 HD.  I was getting a vibration and a  bad clunk in the drivetrain.  Took it to my tranny shop and they found that there was only about 1/2 cup of fluid in it.  Needless to say, it was ruined.  Kinda like only having 1 quart of oil in your crankcase when it calls for 5.  They said there was a crack or a leak of somekind on the top of the case.  It only lost fluid when the vehicle was running and their was pressure to push the fluid out of the top.  The slip yoke was all messed up too.  They ordered me a new transfer case and nickel plated slip yoke and now I'm good to go. (With $2100 less in my pocket)

 

I hope this is not the problem with yours.  Now that you've noticed a problem,  check your fluid often to make sure your not leaking fluid like I was.

 

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