Checked Transfer Case Fluid Level - Fluid Runs Out!

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Jul 3, 2004 | 09:35 PM

rob1994AerostarAWD

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From: Canada

Checked Transfer Case Fluid Level - Fluid Runs Out!

I have a 1994 Aerostar 4.0 with E-4WD. I had just changed the fluid in the rear differential and after that I wanted to check the fluid level in the transfer case. I am not sure if it was ever checked because I don't know the maintenance history of my van. Since I hadn't done it before I assumed the higher-up plug was the filler plug. But fluid ran out onto my concrete garage floor when opening the filler plug. I closed it right away.

So I checked the forum just now and confirmed that I was opening the correct plug in the transfer case. It is the rear passenger side plug that I opened up and this is correct! So now I am confused - if this is the filler plug then why is fluid running out when I open it up? How would it even get so full if this is where fluid is added? Any help would be appreciated.

Note: The rear wheels were jacked up at the time. So the van was not level. I don't know if this would cause it? (not being level)

Thanks,
Rob

Last edited by rob1994AerostarAWD; Jul 3, 2004 at 09:55 PM.

Jul 4, 2004 | 10:53 AM

jkorreck

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Well if it was not level it might cause it if the angle was big enough, gearboxes need to be checked and filled with the vehicle flat. However I work in a quick lube right now while I'm going to school, and I check gear boxes daily, a lot of newer fords and chryslers seem to be overfilled from the factory, but like I said that seems to be a newer vehicle thing in my experience. It is possible that someone else changed to fluid though and overfilled it.

Jul 4, 2004 | 11:22 AM

rob1994AerostarAWD

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From: Canada

Thanks for the thoughts but I thought that jacking the back of my van would actually make it harder for the fluid to run out because the filler plug is at the back of the transfer case. This should bring the fluid lower at the filler plug.

Although if it was over-filled at the factory then that was 10 years ago and then I am going to go ahead and change it. Actually I am going to change it anyway now it seems clear it is over-filled.

Is is possible the fluid in the transmission might leak into the transfer case and over-fill it? I read in one of the threads that there is a seal between them.