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.

 

Nice post Grussel. Thanks for this, especially the pics. Where did you get the gallon pumper thing?

 

Napa sells them

 

Good write up for others to follow.

 

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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I got the hand pump at O'Riellys Auto Parts for $9 and it fits quarts and gallons.

 

Thanks. Very informative when accompanied with the pics.

 

Good write-up. It is an official write-up now....

 

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?

 

Factory recommended is synthetic 75w90 gear oil.