My truck is a 2000 F250 4x4 7.3 diesel 306,000 miles.

My recent project has been replacing the torque converter because of a no lockup condition. I was putting everything back together when disaster struck.

I was adding oil to the transfer case with a small funnel with a short piece of plastic tubing pressed onto the end of the funnel (first mistake). As I poured the oil into the funnel from a full quart of ATF (second mistake). The funnel overflowed and fluid started raining down on me (3rd mistake).

I immediately reacted by moving away quickly and as I did the short length of plastic tubing slipped off the end of the funnel and disappeared into the fill hole of the transfer case (I guess that's my 4th mistake).

After cleaning up a little and cursing a lot I set about to try to retrieve the short piece of tubing out of the transfer case. I drained the fluid from the transfer case (I had managed to get about a half a quart in before the disaster struck). I could see the tubing thru the drain hole but I could not get it out because the drain hole is not a nice big opening like the fill hole. The lower half of it is blocked by something that looks like it could be part of a chain guide or tensioner.

After about an hour I gave up and removed the transfer case to see if I could get the tubing out by some other means.

I could not get it out!!!

I decided to take my chances and leave the tubing inside the transfer case, hoping that it will not get caught in the chain or sprockets.

I have reinstalled the transfer case and filled it up with ATF. This time I used a LONG piece of the same offending tubing (about 6 feet long) which I routed between the cab and the bed to a safe location about chest high.

Why didn't I think of that the first time???

I have searched high and low on the internet and the truck forums to try to find a good picture of the NP273 transfer case with the cases split but I have had no luck. All I can find is a part diagram / list but it doesn't tell me if there is enough room in the bottom of the case for my piece of tubing to reside harmlessly.

I wasted an entire day because of this fiasco. I guess it doesn't matter since I'm retired and have lots of extra time. To say I'm pissed would be putting it mildly. I guess I should be thankfull that the truck did not fall on me in the process.

Suggestions and ideas would be greatly appreciated.

 

not much help but why not just split the tcase in half and remove the tube? All you need is black rtv to seal it back up again

 

I thought about that, but I was afraid spitting the cases was not as simple as it looked and could find no information regarding the tear down procedure.

 

Does this help?



Or this?

 

Thanks for posting those pictures, but they don't tell me if there is room at the bottom of the case for my short length of tubing. What I need is a picture of the cases split with the complete chain in place so I can see if there is space below it. A Youtube video of a transfer case rebuild would probably do it.

 

Next time use this:

Multi-Use Transfer Pump

 

I remember years ago when I worked at a Ford dealer (1972, lol) one tech was doing a clutch. As he pulled the trans, with no dummy yoke, the gear oil ran out the tailshaft, and all over him. Doh! I suggested to use a dummy shaft when he put it back in, but no, he forgot, and did it again, and he took another gear oil bath. Nothing more I could say to him!