well I've been working on this d1 ever since I picked it up last month. I just now pulled the plug on transfer case and about 2 spoonfuls of oil came out and there were some metal shavings on the plug. It hasn't left my driveway since I've owned it, but I did drive it about 100 miles home when I bought it..and I have no idea how long PO ran it dry.

 

Got any pics of the shavings? Are they really small or large?

 

they were small and about what you would expect for normal wear..so maybe it'll be ok..I guess I'll find out soon.

 

I imagine with that little fluid, all the shavings that would normally be suspended in the fluid of a full tcase would be concentrated in the little bit that was left, making it look worse than it is, although running it dry can't help none.

 

Put fresh fluid in it and run it till it grenades. Whether you get 10 miles or 10,000 miles, it gives you time to get the money together for another one.

 

I had some in my case too. Just flushed it 3 weeks ago. Been 4 wheeling twice and it is working just fine. I have 180k and expected this wear.

 

oh yeah I'm going to keep using it, this is my off-road fun rover. It just sucks cause the transfer case was the ONE thing on the rover I thought was solid.

 

Sounds like a horrible thing to do to a transfer case. I would definitely refill and go from there.

If it was almost dry, the shavings could be clinging everwhere. Maybe put the cheapest stuff in it, run it a while, drain and refill with 85-140.

 

That is exactly what I am doing. Put in 80 90 and this weekend I am swapping it out.

 

I think in the long run, that is the better approach. See what drains out this time. I went with the 85-140 after draining some old black stuff out. Minimal shavings. A fair amount did drain out but it was a little low and old looking.

Much quieter operation now. It should last a while.