Transfer case fill plug - does this sound right? (1 Viewer)

[CarcaineProblems]

I'm doing some maintenance on my '97 land cruiser and one of the items on my list is to change the transfer case fluid. Now, I have no problems doing the front or rear diffs, but I don't think I've got the right "hole" for the transfer case fill.

The drain plug is easy to find. The fill plug, or at least what I thought was the fill hole, seems real narrow and when I pulled of the hex bolt, it had a spring inside it. Is this right?

The best way to describe where this is would be to lay on your stomach w/ your feet at the back, look towards the front. Once I found the t-case and the drain, the fill plug was up and to the left of the drain (towards the drivers side), at the top of the t-case. Pointing downward.

Is this right? Not having the FSM is killing me - this Chilton manual is a piece of $hit. C-Dan, you should stock these FSM's instead of a 2 week wait!!!! (but thanks for the brake parts C-Dan!! it made a huge difference)

 

[IdahoDoug]

Unless someone replaced it, the fill plug looks exactly like the drain plug from the outside. A 24mm (I think) flattish bolt. I can't figure out your description, but stick your pinky in whatever you removed and see if you smell gear oil on it. The spring thing has me puzzled. The fill is on the rearward upper face of the center diff.

DougM

 

[80cruiserscool]

i just did mine last week. the fill plug is on the driverside or left side of the tcase. it is about half way up,and was stated before it has the same size plug as the drain plug unless someone has changed it to the allen head plug?
hop ethis is clear as mudd!!
;p

 

[OGBeno]

Hey Dangler:

Not sure if the fill plug points downward as you explained it. The drain plug is literally underneath the flimsy skid plate held onto place by three 12mm (IIRC) bolts. I believe, actually, the drain plug is at the tail end of that skid plate, towards the back of the truck..

The fill plug, if you turn your body and lie on your stomach underneath the rig and look up, is to the left of the drain plug but literally facing you. It is, as Doug mentioned, the same size--24mm, 6-sided--and is near the lefthand side of the xfer case (driver's side), right near the edge of the lefthand side of the xfer, not too far up.

As many have mentioned (and judging by your sig line of rigs, you already know this), it's worth while to take the fill plug oof first before you empty the xfer with the drain plug. Many horror stories of people not being able to take their fill plugs off after having drained the xfer...

If you want, I will be happy to take a picture for you in the AM (friday) and email it to you...drop me a PM.

Best regards.
-onur
Akron, OH

 

[CarcaineProblems]

yeah - i think its the new hex style plug like C-Dan sold me for my diffs.

IdahoDoug - not sure if I understand your description of "The fill is on the rearward upper face of the center diff" care to elaborate.

This has got to be it, i think?!?!?!

Thanks

 

[IdahoDoug]

If the gas tank had wheels and drove forward into the center diff, it would hit the face of the center diff that's got the fill plug on it. That's what I mean. It's not as high up as you'd expect, but is toward the driver's side of the vehicle rather than in the center. Stick your pinkie in whatever you've opened up and it should solve the mystery.

DougM

 

[RavenTai]

Sounds like you found a shift detent, there is probably a ball under that spring, could also be the pump relief valve. the fill port has no spring and does not face up, it faces aft, it is not at the top of the T-case it is near the middle closer to the bottom than the top, it only takes 2 quarts

 

[e9999]

oh no... It has a spring you said?
Dangler, tell me you didn't remove the factory sealed adjusting transfer case helium bearing knob!!!

 

[CarcaineProblems]

LOL take it easy on the newbie I figured it out. I was trying to make the job of filling it harder than it should be.

Take a look at the first pic: The upper right circle is the first bolt I removed, the one wiht the spring. The lower right is obviously the fill plug.

So what the heck is it???

 

[RavenTai]

Pic?

 

[IdahoDoug]

Cool, glad you figgered it out....

 

[CarcaineProblems]

Here's the bolt \ spring I removed from the hole in the upper right corner of the first pic

Any guesses on it?

 

[RavenTai]

Here's the bolt \ spring I removed from the hole in the upper right corner of the first pic

Any guesses on it?

that woudl be the transfer case oil pump relief valve, under the spring is a ball under the ball a plunger, torque on the plug is 22' lbs,

I cant find the torque for the drain and fill port's, had trouble last time I looked also.

 

[CarcaineProblems]

Raven - thanks for heads up on the transfer case oil pump relief valve - I'll take it back off and torque it properly.

Thanks guys!

 

[4x4CPOSEADOG]

27 ft lbs of torque for both transfer fill and drain plug. Have fun!

 

[Curran]

I made this same mistake about two weeks ago.
Glad I'm not the only one.

 

[ferdball]

I just did mine just hoping that the plugs would make sense and you're right it was a bit odd that the fill plug was so low. seemed like 2 quarts was not going to fit, especially when it seemed like 4 quarts came out.... and it was real thin and reddish brown, lots mo gunk on the magnet too...

filled with about 2 quarts of m1 75-90w

 

[Cj80cruiser]

I just did mine just hoping that the plugs would make sense and you're right it was a bit odd that the fill plug was so low. seemed like 2 quarts was not going to fit, especially when it seemed like 4 quarts came out.... and it was real thin and reddish brown, lots mo gunk on the magnet too...

filled with about 2 quarts of m1 75-90w

The reddish brown wasn't transmission fluid was it? Some Tcase's have been accidentally filled with it before I think.

 

[ferdball]

hope not... All's I know is that it seemed a lot thinner than the oil coming out of the pumpkins. looked more like motor oil but dont think it was ATF, that stuff is not reall oily slippery....???

is it normal to see the orange gasket stuff on a t-case from the factory or does this mean it's been in to?

 

[Cj80cruiser]

hope not... All's I know is that it seemed a lot thinner than the oil coming out of the pumpkins. looked more like motor oil but dont think it was ATF, that stuff is not reall oily slippery....???

is it normal to see the orange gasket stuff on a t-case from the factory or does this mean it's been in to?

My gasket seals are orange and I see it very clearly everywhere so you should be good there. The Tcase oil should be the same thickness as the the diff oil. I believe you already knew this since you compared the two but I just wanted to make sure. If your Tcase isn't making any crazy loud noises I wouldn't worry about it. Fill with the correct stuff this time and call it good.