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Old 11-26-2009, 09:27 AM
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Default D1 Transfer Case Fluid Change with Pictures

The cover plate on my transfer case was leaking, so I decided to reseal yesterday and change the gear lube to a heavier weight. I use a 1/2" drive breaker bar to remove the fill plug. You can pull the brake cable out of the way so the breaker bar fits in the space. See pic. I then drained the fluid and then removed the cover plate. The cover plate bolts are 10mm and you have to use a wrench on the top 3. I cleaned the mating surfaced with carb cleaner and 0000 steel wool and then a clean shop rag. Butter the sealing edge of the cover plate with RTV and let sit for 15 minutes before reinstalling. Tighten bolts from the center out using a cross pattern. I use Teflon tape on my fill plug and it always comes out easy. I used a hand pump on a gallon container of gear lube and it is a much cleaner process of refilling than using individual quarts. Leak fixed and fresh lube. I already noticed the transfer case runs quieter now and the whine is gone when I let off the gas and coast. Changing the lube and resealing the cover plater took about an hour and a half. If your just changing the lube you should be able to do it in under an hour.
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D1 Transfer Case Fluid Change with Pictures-transfer-case-001.jpg   D1 Transfer Case Fluid Change with Pictures-transfer-case-003.jpg   D1 Transfer Case Fluid Change with Pictures-transfer-case-004.jpg   D1 Transfer Case Fluid Change with Pictures-transfer-case-005.jpg   D1 Transfer Case Fluid Change with Pictures-transfer-case.jpg  


Last edited by grussell; 11-26-2009 at 09:31 AM.
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Old 11-26-2009, 09:35 AM
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Nice post Grussel. Thanks for this, especially the pics. Where did you get the gallon pumper thing?
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Old 11-26-2009, 09:44 AM
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Napa sells them
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Old 11-26-2009, 11:32 AM
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Good write up for others to follow.
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Old 11-26-2009, 04:32 PM
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Excellent!
It's a good idea as well to loosen your filler plug first. If you have any issues with it you won't gwet stuck with a box with no oil.

Also I use Hylomar on all my fill and plug threads. It is just a quick spray and your done.
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Last edited by cranky; 09-11-2011 at 01:06 AM.
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Old 11-29-2009, 08:01 PM
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Quote:
Originally Posted by Robover01 View Post
Nice post Grussel. Thanks for this, especially the pics. Where did you get the gallon pumper thing?
I got the hand pump at O'Riellys Auto Parts for $9 and it fits quarts and gallons.
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Old 11-29-2009, 08:07 PM
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Thanks. Very informative when accompanied with the pics.
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Old 11-30-2009, 07:56 AM
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Good write-up. It is an official write-up now....
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Old 01-14-2010, 11:57 AM
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Question.... In my Mobil lube recommendation guide it calls for "special Lubricant Fluid" for the transfer case , in other words, there is no recommendation. Will a simple GL-5 Gear Oil work? I see you used a "heavier" weight. What is the factory recommendation?
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Old 01-14-2010, 12:02 PM
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Factory recommended is synthetic 75w90 gear oil.
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11, 2003, case, change, changing, disco, discovery, fluid, land, lr, oil, rover, transfer, transfercase, whine

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