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I have a 2005 F150 5.4L 4R75E. FX4 BW4406
mileage is 115K, bought the truck new in 2005. It is a July 05 build.
I have opened and disassembled the transfer case;.
The transfer case fluid when drained was dark red, very dark red with a burnt smell. This was a surprise since the fluid had been in for less than 30K miles. The fluid on the transmission dip stick appears bright red.
Previously when the transfer case fluid was replaced the old fluid had always had a bright red color, not dark with a burnt smell.
There was no metal found in the fluid or on the magnet. The only debris found inside the transfer case was a small amount of black fiber around the outside edge of the magnet. The fiber became a black smear when wiped off the magnet with a paper towel. The flat sections of the magnet did not have any of the debris.
The case is exceptionally clean inside except for the black material baked onto the output shaft splined areas and in the smooth areas of the shaft not in close contact to other metal parts. (see attached photos)
Also the reduction hub appears to have been overheated due to the multi colored rings on the smooth portion of the hub, no distortion just the rings. (see attached photo)
There were no drivability issues with the truck, no codes pending or posted. The truck is not overheating, the transmission is not overheating. If anything the transmission fluid is below normal at 145 F. Not the transfer case fluid as there is no temp sensor to monitor in the transfer case.
Both 2 WD, 4 HI and 4 LO are working fine, with no issues shifting between drive modes.
Is the material baked on the output shaft normal?
What would have caused the heating necessary to bake this material onto the output shaft?
What would have caused the heating to leave the rings on the reduction hub?
The oil passages are all clean, the filter in the oil passage of the output shaft is clean, the filter on the pickup tube is clean with 0 debris trapped in either filter..
For me the obvious answer is the oil pump is not pumping enough oil to cool the metal. BUT this is a guess, it's a lot of work to get into this thing and I hate to proceed on a guess.
Would appreciate any input from anyone that has seen this before and knows how I can fix this.
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