Hello everyone! I have a 1990 F250 4x4 with E4OD. I haven't had the truck very long, but I just realized that 4x4 didn't work. I narrowed it down to the transfer case. When I pulled the old transfer case off it was really, really full of fluid. I would estimate several quarts. I didn't pay much attention to it at the time.
So, I sourced another working transfer case. When I bought it I drained all of the fluid out of it and cleaned it up a bit. I installed it on the truck, reconnected all of the drive shafts, and removed the fill and drain plugs in order to prepare refill it. When I removed the drain plug about a half a quart of fluid came out.
Where in the world did this fluid come from???

 

From the trans... input t case seal was probably not good anymore causing fluid to transfer.. that's usually what happens

 

How does one go about fixing this?

 

A new input seal and a trans gasket, adjust t case fluid accordingly

 

I see that there's a seal on the transfer case input shaft, but is there a seal on the transmission output shaft that I need to replace as well?
Does anyone have any part numbers by chance?

 

This one

And


Ford used a opened end tail housing, so use the gasket supplied by Ford or your local transmission shop should have one or rtv

 

Also, when I installed the new transfer case, I just used Ultra Grey RTV instead of a gasket between the transmission and transfer case. Do you see any issues with doing it this way?

 

I used white Tub & Tile silicone. It's been a good year so far, no leaks(from there, anyway <_< )

 

Really?? That's very interesting!

 

So, just so that I'm clear, replace just the input seal on the transfer case. There's nothing to be replaced on the transmission output, right?

 

Correct, it is just a open housing on the transmission side, you will see a big ol hole. Clean area and install gasket or rtv and you're good to go

 

RTV is fine, but I prefer the gasket, just my preference though.

I had a hard time finding it local, so I got it here:

Transfer Case to Adapter Gasket 4WD 4 x 4 Ford Borg Warner 1345 1350 1354 1356 | eBay

 

d-day, you sir, are the man! I appreciate the info. Now I've just gotta get the motivation to take it all back out now.

 

Lol I don't know about being the man haha. Just like to help out a fellow member when I can or if I know how. Drive train I am pretty set on, I am also still new to a IDI

 

On a side note these are probably one of the easiest engines & vehicles to work on.. I am comparing to vehicles today, I work for Chrysler/ dodge and I would have nothing to do with a new $75,000 truck, I would take my old 85 any day