Ford Super Duty (1999-2016) :: Overfilled Transfer Case Or Leaking Transmission Output Seal
Mar 22, 2016
I just changed transfer case fluid on my father's F-350 for the first time in 13 years. (over 230k). Removed fill plug first and fluid gushed out of the fill hole unexpectedly. Did not have catch pan ready, so made a mess. I thought it was just over filled form the factory, but too much was coming out to be simple overfill. Almost 2 qt came out of the fill plug.
Did some google search and found many Ford trucks have failed transmission output shaft seal and transmission fluid leaks out to transfer case, causing transfer case to overfill. I am yet to check transmission fluid level, but considering how much came out of it that probably is the case.
Now, how bad of the problem this really is? Will overfilled transfer case cause some serious problem? 4x4 is rarely used (once or twice a year in winter) on this truck and from what I understand transfer case doesn't really do anything in 2WD other than just passing output from transmission through.
There are no fluid leaking outside and repairing the seal would be a too much of work for me.
Also changed rear differential fluid for the first time and I was surprised how clean the fluid was. There were thin layer of black sticky residue (sludge?) covering everything, but the fluid itself looked clean and no visible metal shavings. I guess that is why Ford said it does not require change under normal condition.
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I got a 97 f150 4x4, 4.6 and I had the shop replace the seal 3 times and it's still leaking, the seal where the driveshaft goes into the t case, I call it the slip yoke seal, they said the bushing inside looks good, there doesn't seem to be a whole lot of play in the driveshaft, it doesn't seem to leak a whole lot, I'm about ready to just forget about it and just run it, they put a seal from oreillys in, it seem to be leaking out of the bottom hole on the seal...
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I had my truck at the shop today and it was determined that the transfer case front driveshaft seal is leaking and the gasket between the transmission and transfer case has also failed. The shop wants a reasonable amount to fix it but they need the truck for 2-3 days. It doesn't appear to be that difficult of a job to remove the transfer case. Am I missing something? Dropping off the truck and leaving it for a few days is the difficult portion......if they could do it in a day I'd just pay them and be done with it. So my thought was to pull it and just drop it off so they can replace the seals and fix any other issues.
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Made a short run to get lumber yesterday and when I got home the truck smelled hot I checked it out and found a transmission oil leak at the rear of the transmission in front of the transfer case. can not really see what is leaking only has 22,000 miles. What may have happen. 2011 F250 4x4 6.7....
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For about a week or now i have been trying to track down a sound from my truck, i had another post up and was finally with jhl3 able to determine that the sound is coming from my transfer case. The other thread with video of sound is located here : [URL] .... I've got a little bit of time to mess with i now
Quick rundown, began hearing odd sounds about a week ago, determined that it is transfer case. Front hubs are unlocked, esof switch is set to 2wd. Can not turn front drive shaft. I just put some zip ties on front drive shaft and went for a short spin, determined front drive shaft IS turning. Hubs are not locked and 4x4 is not engaged, did the sharp slow turn test, no feel of pull from front end.
Im not quite sure where to go from here, going to check connections at tcase motor and some relays.
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Originally it would light up on the dash, the hubs would lock, but the transfer case would not shift in to 4 wheel. Followed the troubleshooting I've found, was receiving power at the connection on the shift motor but it was not turning.
So I went and bought a new motor, installed it, still wouldn't turn. (with the motor off the transfer case but electrically connected). So I found a few more replies about the relays, swapped them, nothing.
Removed the covers and manually flipped the connection, nothing. Now my hubs are locked, transfer case is not, and I get nothing when I change the switch on the dash. (no lights, no hub click shift, no 4 low, nada). All the fuses are good, just doesn't work.
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New floor mats. My truck is going to be 10yr old and has the original King Ranch floor mats. I want some heavy duty rubber ones that will fit around my manual transfer case lever. I ordered the Weathertech digital fit liners and I am not happy with them so they are headed back tomorrow. They have a heavy duty all weather mat but not sure how it will work with my shift lever on the floor. Husky liners/mats look nice and heavy duty but won't accommodate the floor lever.
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The transfer case on my 2004 F350 6.0L 4WD DRW, 230K miles, just blew to pieces Sunday night. See images below. What could cause this?
I just had the front drive shaft rebuilt with new universals and ball. It was making a metallic squealing noise after this.
I noticed that the front drive shaft did not spin freely when parked in nuetral and set for 2WD. I thought the front drive shaft would only engage when in 4WD.
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We have a 2000 F250 7.3L Diesel. A few years ago we switched out the auto hubs for manual Warn hubs. We've had no problems with 4x4 since that time, until now!! The 4x4 Hi light is on and the transfer case is engaged. Since the hubs are manual we have them unlocked, however we can't get the 4x4 to disengage. At one point, tried changing to low and it hesitated but finally went in to 4 Lo, then we had a hard time getting it out of 4Lo and back to 4 Hi. Here's what we've tried--checked fuses, checked and replaced relays, checked wiring connection at the transfer case. Husband used volt meter to test power at transfer case wiring connector--showed 0.5 volt of power with the key on. No change in reading. Checked power at relay--about 14.5 volts there. Took truck to repair shop but their computer could not communicate with the GEM.
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Trying to stay up on my maintenance on my '11 f-350 diesel. It just turned 59k. I can only find Ford's recommended service interval for changing the fluid in the transfer case listed in the "Special Operating Conditions" section of my Scheduled Maintenance Guide for towing, delivery, off-road and dusty conditions at 60,000 miles. I tow some, but maybe 20% of the time, I end up driving a lot of stop and go though.
So I found this nice how to online "Guzzle's Transfer Case Fluid Change" - it's for a 02 heavy duty, is it about the same on the newer diesel trucks?
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I found that my transmission was low on oil but couldn't find a leak. What I did find is that the seal in the transfer case was letting trans fluid transfer into it and then it would leak out the out put seal. I purchased the new seal and gasket and repaired it myself in about 3 hours. I removed the rear drive shaft and removed the front drive shaft from the transfer case alone or you can take it out completely if you want.
Drained transfer case unplugged wiring and one vacuum line. Unbloted from trans and removed using trans jack. The bolts are not the easiest to get to. i used a 3/8 ratchet to break them loose then used a stubby 3/8 to get them out because they are around 2 inches long. Once down I had to jack up the truck to get it out from under it. I removed the old seal and installed new one cleaned everything up and installed with a new gasket.
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2001 F250, 7.3L ... After much diagnosis, I've found that the 4 positive feeds to the transfer case relay base have no power to them. The fuse that feeds them (#17 CJB) is fine and when I jump from the fuse hot side directly to the transfer case motor contacts on the relay base, it shifts fine. As far as I can tell, there is only one wire leading from that fuse so there must be a junction block somewhere that splits it into the 4 wires that feed the relay block. I've looked underneath and found nothing. How the 1 wire gets split into 4? On diagrams this junction point is labeled, but I don't know where to find that.
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Truck is an 03 F350 with the 6.0. It sometimes sounds like the shift motor on the transfer case is trying to engage. It has the vacuum system which is blocked off. Warn aftermarket hubs. Switch on the dash with 2wd, 4wd and 4 low.
It's kind of an off and on thing. Try to engage for a few or more seconds then nothing for awhile then repeat. It sounds like it's at the transfer case. It could very well be coming from firewall/engine bay area as well. Is there anything between the dash switch and the motor?
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I'm in the process of changing my shift motor on my 04 f350. I can't get it off because of a broken bolt. The previous owner must have done this before, and snapped the head and some of the shaft off, so it's basically an alignment pin that's recessed into the hole on the motor. For some reason it's holding the motor on, even though I don't think the hole is threaded. Any way to get it off. I'm thinking that taking a MAP gas torch to the casting on the motor may be my best bet.
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I just purchased a F250 Gasser with the 6.2. I made sure to get it with the 4.30 rear to babl to tow a little better when i upsize the tires a little. Where I can find the drive output ratio from the transmission?
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I noticed the other day after my truck was parked on a bit of a angle there was diff oil from the passenger side on the ground. reading a bit on here i learned the axle seals are way in the front housing close to the front diff. and yesterday driving a heavy load around my front brake driver side got stuck on a bit and over heated and was smoking, couldn't even touch the rim it was so hot. anyway about this axle seal i got the hub off right now but cant seem to pull out the axle assembly through the knuckle but i see i have to pry and most likely wreck that seal. Looking for a link of piuctures or how to replace the axle seals in the housing.
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Just had my truck in for an oil change at dealership and wanted them to check for oil leak seeing as I started getting drops on my driveway. When I pick up the truck they told me the front crank seal was leaking and possibly the rear main seal. Front was gonna be 650 bucks and the rear was gonna be 1020. Ended up taking truck to local diesel shop and they replaced front crank seal for 300 and said the rear main looked fine. Tech also told me the old seal looked worse than some that came out of engines with 3 times as many miles. 6.4L ...
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99, F250, 4X4, V10, 72,000 miles. I have had the front axle seals replaced three times in the past 3000 miles, and the right continues to leak. My mechanic screwed up three times?
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Pinion seal on my truck is leaking. At auto parts store they gave me National seal part number 4278. It does not fit it is too small.I went back and other seal they have is too big. What is the part number?
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I have my 03 F350 which unfortunately has a sunroof...which now appears to be leaking. Around the entire seal inside is damp about 1/2" out into the headliner. I looked up top and didnt see anything out of the ordinary..but the back of the sunroof is flush with the roof and the front is about 1/4" down, and if you press on it...it sinks about another 1/4". My questions here are...how do i fix this leak, is there a seal that needs to be replaced? and is that play in the sunroof normal or is something wrong?
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The rear hub outer oil seal on my 05 350 is leaking. The 350 Super Duty Twin Cab was never imported into the UAE so can I use the same seals as the Excursion or another Ford vehicle?
Failing that do we know the name and part number of a seal manufacturer whom I might be able to source from in Dubai? Ford don't make the seals them selves so there must be an alternate source for these things surely?
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