overfull Transfer case

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Apr 11, 2021 | 02:35 PM

B931070me

Thread Starter

New User

Joined: Dec 2020

Posts: 10

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From: Happy Jack, Arizona

overfull Transfer case

97 Ford F-250 HD 460, 4x4

Kept putting trans fluid in my 4AOD trans. Found the transfer case to be overfull.
Can I assume there is a seal between the trans and transfer case that is bad?

Thanks,

Apr 11, 2021 | 02:52 PM

WWR

Cargo Master

Joined: Dec 2015

Posts: 2,911

Likes: 504

Yeah, I've never fully understood this because the tailshaft housing should only have a little fluid in there and the t-case input seal is pretty high relatively but supposedly your situation is not uncommon.

I had a friend who experienced it years ago and Makuloco specifically addresses it, albeit on '04-08 F150s, go to 31:30

Apr 11, 2021 | 05:10 PM

SuperDutyScaler

Lead Driver

Joined: Nov 2008

Posts: 8,449

Likes: 70

From: South Jersey

Yes the seals are no good between the trans and t-case. The trans pump circulates the fluid and the return line goes right into the tail section to lube the bearings. So yes there is pressure while it's running and when the seals go bad it pushes the fluid right past it and into the t-case.
IMMEDIATELY fix this by the way

Apr 12, 2021 | 02:52 PM