Yesterday I changed transfer case oil with 85W140. Took 4 hrs with hand pump small trickle at a time.

Anyway, the truck was on a slight angle because there's not a level spot on my whole property. I added 1 whole gallon and still no dribble from the fill hole. The owner's manual says 2.4. Did I overfill? Am I not supposed to fill until it starts dripping from the fil hole?

DO I have to empty and refill to 2.4 quarts or can I leave 1 gallon in?

Or, better yet, how do I measure whether I have 2.4 quarts without emptying what already in?

 

Refill supposed to be less than 2.4.

Jack and place adequate support such as lumber beneath tires to level. Excess should drain out.
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Last night I parked on level ground and opened the fill plug to the transfer case. No excess gear oil came out.

Do I empty the transfer case to 2.4 quarts?
What is the harm in having 1 gallon in transfer case?
Do I fill it to plug level?

Add this to LR Disco House of Mystery. Why would the fill plug be located above the desired fill level?

 

If you parked almost on level ground, there is no way you can overfill to make t-case take
1gallon of gear oil,! Extra oil will just simply not go in from fill plug,!! Unless if you park with nose down very steep,, even then when you park on level ground and open fill plug the extra oil will simply pour out,,
Either you making a mistake and didn't put in 1 gallon of gear oil,, or you filled it from a different place than fill plug,,

 

The D2 manual I have says that the approximate volume to refill the transfer case is 4.1-4.8 pints (p.09-01). That's a little over half a gallon.
It also says to fill to the bottom of the filler hole (p.10-19).
I don't recall how much I put in mine when I changed it. I know it was way less than a gallon and it was coming out of the fill hole. Are you sure you have the right filler hole and you're not putting it into the transmission?

In addition, it says that the transfer case oil should be 75W90 gear oil. 85W140 is a long way from that. Perhaps that's why your fill time is extraordinarily long.

 

Oh sh*t,

I put 1 gallon in #12 not #11. What now?





I emptied out of #20

 

Drain it and refill through #11.
Be warned, it's tricky to get to. There's a big wiring loom in the way (at least on mine).

 

I will do that.

What was filled in #12? Is it separate internal compartment from #11? Is anything ruined with 1 gallon in #12?

Drove about 10 miles yesterday. Did I drive with no oil in transfer case by emptying #20 and filling #12 as opposed to #11?

 

It's hard to tell, but it doesn't look to me like the #12 hole is any higher up on the case than the #11. I don't know how you would have gotten so much more oil in there than it's supposed to hold.
10 miles isn't too far though. I would refill and keep an ear out for any unusual whining or grinding noises. I believe the t-case is a pretty tough beast so it may not have suffered any damage.

Is there any particular reason why you're using such heavy oil though?

 

Don't need to drain oil & refill,,
Just park at level ground and open #11, the real fill plug,!! Hahaha, and extra oil will pour out, then put plug back in place & you are good to go,, no harm done,,
(No harm done to seals in10 miles, you are ok),