I just changed the fluid in my 03 transfer case. It took right at two quarts to fill...Here is the weird part when I took the "fill" plug out first almost a quart of fluid came out. Then I pulled the "drain" plug and another two quarts came out. I caught it all and put it in a gallon jug to see how much and it was 3/4 full when done. I don't know how you could even get that much in it started dripping out of the fill hole at two quarts for me...Any Ideas.

Thanks

 

I haven't the foggiest idea unless they used some kind of flushing machine. The fluid should come to the bottom of the fill hole. Always take out the fill plug first before draining it, which it sounds like you did. It would suck not being able to get the fill plug out and have an empty t-case.

 

the seal between the trans and transfer case is allowing the fluid from the trans to go to the transfer case when the vehicle is parked on an uphill incline.thats why your case is overfull.

 

Maybe, if this was your first fluid change for the transfer case, it was "bench filled" upon assembly. It is easy to check...drive for a few miles and inspect fill plug for fluid level.

 

Is it a "bad" thing for the T-case and tranny to share fluid like this? In other words, should the problem be corrected immediately?

 

the only thing i would really worry about is my fluid level in the transmission getting low and cause a possible problem in the trans.but my opinion is to get it fixed so you dont have the worry of the fluids becoming low.

 

I had this problem with my 03 expedition. Its the seal between the transfer case and the tranny. This can cause some real damage to the tranny if it is under heavy load due to excessive fluid going to the tranny. If you tow or hill climb lots get this fixed immediatly or you'll be replacing tranny

 

Resurrecting an old thread here because I had the same issue and just rebuilt the transmission (4R75W) on my truck. There is no seal on the back of the tranny that can be serviced. There are two steel sealing rings that keep the pressurized fluid lubricating between the output shaft & the rear bushing from escaping in to the extension housing. These sealing rings can be replaced only after disassembling the entire transmission -- the output shaft/ring gear assembly is the last thing that comes out of the barrel of the transmission case.

I had an overfilled TC and suspect that this was either done at the factory or happened when the previous owner had the transmission flushed. My advice would be to monitor the tranny fluid levels and leave it alone. However, if your TC fluid is low and neither the front nor rear output seals are leaking, then you need to drop the TC and replace the input seal.