Transfer case leak

1. Be sure to run your car (in 4WD) for about 5-10 minutes or so to warm the oil up and be sure to park on a level ground.First we need to gather our materials. This is what I used for my oil change:Initial expenses

• Oil Catcher - $10 at Pep Boys
• Fluid Pump - $5 at Pep Boys
• 24mm wrench or ratchet (assumed ownership)
• 12mm? and 14mm? sockets to remove skidplate

Transfer Case Change Expenses

• 3 Qt 75W90 Gear Oil - $21
• (I used Redline from myoilshop.com)

2. Locate the Transfer Case.
Remove the Fill Hole plug first, then place your oil catcher in position, and remove the drain hole plug.
While the oil drains, clean off the drain plug.

3. When finished draining, replace the drain plug, and proceed to pump the fluid into the fill hole.
I filled until the fluid overran, but you can check the fluid by sticking a pinky into the hold and checking the level.
Replace the fill hole plug, and done.

Depends on your engine.

1980 JEEP CJ-7 2.5L 4-cyl Engine Code [B]
CAPACITIES
Engine, GM without filter..........2.4 quarts[1]
Wix Filter ........ 51040
Cooling System, Initial Fill..........8.0 quarts
Automatic Transmission, A904, 30RH Initial Fill..........4.0 quarts[2]
Automatic Transmission, A999, 32RH Initial Fill..........4.0 quarts[2]
Automatic Transmission, Total Fill
3 speed A999, 32RH..........8.4 quarts
3 speed A904, 30RH..........7.0 quarts
Manual Transmission, 4-SPD, SR-4..........3.0 pints
Manual Transmission, 4-SPD, T176..........3.6 pints
Differential, Front..........2.5 pints[3]
Differential, Rear..........4.9 pints
Transfer Case,..........4.0 pints

1. Add extra oil when replacing filter. After refill check oil level.
2. With engine automatic transmission operating temperature, shift through all gears.
Check fluid level in NEUTRAL and add fluid as needed.
3. 1984-1992 Models with command-Track, add 5 oz of 75W-90 GL-5 to shift motor housing opening.

TORQUES
Oil Drain Plug.....25 ft-lbs
Manual Transmission T176
Fill Plug.....15 ft-lbs
Drain Plug.....15 ft-lbs
Manual Transmission SR4
Fill Plug.....20 ft-lbs

1980 JEEP CJ-7 4.2L 6-cyl Engine Code [C]
CAPACITIES
Engine, without filter..........5.0 quarts[1]
Wix Filter..... 51522
Cooling System, Initial Fill..........11.0 quarts
Automatic Transmission, A904, 30RH Initial Fill..........4.0 quarts[2]
Automatic Transmission, A999, 32RH Initial Fill..........4.0 quarts[2]
Automatic Transmission, Total Fill
3 speed A999, 32RH..........8.4 quarts
3 speed A904, 30RH..........7.0 quarts
Manual Transmission, 4-SPD, SR-4..........3.0 pints
Manual Transmission, 4-SPD, T176..........3.6 pints
Differential, Front..........2.5 pints[3]
Differential, Rear..........4.9 pints
Transfer Case,..........4.0 pints

1. Add extra oil when replacing filter. After refill check oil level.
2. With engine automatic transmission operating temperature, shift through all gears.
Check fluid level in NEUTRAL and add fluid as needed.
3. 1984-1992 Models with command-Track, add 5 oz of 75W-90 GL-5 to shift motor housing opening.

TORQUES
Oil Drain Plug.....30 ft-lbs
Manual Transmission T176
Fill Plug.....15 ft-lbs
Drain Plug.....15 ft-lbs
Manual Transmission SR4
Fill Plug.....20 ft-lbs

1980 JEEP CJ-7 5.0L 8-cyl Engine Code [H]
CAPACITIES
Engine, without filter..........4.0 quarts[1]
Wix Filter..... 51258
Cooling System, Initial Fill..........13.0 quarts
Automatic Transmission, A999, 32RH Initial Fill..........4.0 quarts[2]
Automatic Transmission, A904, 30RH Initial Fill..........4.0 quarts[2]
Automatic Transmission, Total Fill
3 speed A904, 30RH..........7.0 quarts
3 speed A999, 32RH..........8.4 quarts
Manual Transmission, 4-SPD, SR-4..........3.0 pints
Manual Transmission, 4-SPD, T176..........3.6 pints
Differential, Front..........2.5 pints[3]
Differential, Rear..........4.9 pints
Transfer Case,..........4.0 pints

1. Add extra oil when replacing filter. After refill check oil level.
2. With engine automatic transmission operating temperature, shift through all gears.
Check fluid level in NEUTRAL and add fluid as needed.
3. 1984-1992 Models with command-Track, add 5 oz of 75W-90 GL-5 to shift motor housing opening.

TORQUES
Manual Transmission T176
Fill Plug.....15 ft-lbs
Drain Plug.....15 ft-lbs
Manual Transmission SR4
Fill Plug.....20 ft-lbs

Oilman

Hi there,

CAUTION

New transfer case lubricant must be installed any time the transfer case has been submerged in water. Also, transfer case failure CAN result if the correct fill procedures are not followed.

NOTE: The transfer case is lubricated for life and is not to be checked unless a leak is suspected or a repair is necessary.

1. Remove the drain plug and drain the transfer case.
2. Apply sealant to the drain plug threads and install the plug.
3. The fluid level must be even with the bottom of the filler hole with the vehicle on flat, level ground.

To Fill:

1. Remove the fill plug and fill the transfer case with SAE 75W-140 synthetic gear lubricant.
2. Apply sealant to the fill plug and install the plug.

Cheers,


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Locate the fill plug in the center of the transfer case facing the rear. The fill plug is a hex head bolt.

Remove the fill plug and check the fluid level. Insert the short end of an L-shaped Allen wrench into the hole. Spin the Allen wrench slightly and remove it. Some fluid should be present on the tip if the unit is full.

Attach a screw-on hand pump to a bottle of Mopar ATF+4 type 9602 automatic transmission fluid. Insert the other end of the tubing for the hand pump into the fill plug hole on the transfer case.

Pump fluid into the transfer case until the fluid is flush with the bottom of the hole. A small bead of fluid will drip out of the hole when the case is full.

Reinstall the fill plug and torque it to between 15 and 25 foot-pounds of torque. Hand-tightening the plug and turning it 1/2-half turn further with a socket wrench is equivalent to 20 foot-pounds of torque if you do not have a torque wrench available.

CAPACITIES
Engine, 2WDwithout filter..........3.5 quarts[1]
Engine, 4WDwithout filter..........4.0 quarts[1]
Cooling System, Initial Fill..........8.5 quarts
AMSOIL Antifreeze and Engine Coolant
Automatic Transmission, Total Fill..........7.4 quarts
Manual Transmission, 2WD..........4.2 pints
Manual Transmission, 4WD..........8.4 pints
Differential, 2WD Rear..........3.2 pints
Differential, 4WD Rear..........2.7 pints
Differential, Front..........2.7 pints
Transfer Case,..........4.6 pints

1. Add extra oil when replacing filter.
refill check oil level.

TORQUES
Oil Drain Plug.....22-29 ft-lbs
Transfer case
Fill Plug.....18-25 ft-lbs
Drain Plug.....18-25 ft-lbs
Manual Transmission
Fill Plug.....18-25 ft-lbs
Drain Plug.....18-25 ft-lbs

It should be listed in the owners manual, but because of different oil cooler setups you may have to do the change yourself and add oil until the correct level is established..... for the first oil change.
Most likely 7 liters,but start with 5,run the engine to fill the oil filter,let it sit for 5 mins and recheck and fill to full.
Note the amount needed for next time.

GM Full-Size Trucks 1980-1987 Repair Guide

Transfer Case - FLUID RECOMMENDATIONS
The type of lubricant used in the transfer case varies with model year and type of transfer case. Refer to the list below for the type that applies to your truck.

1980
Conventional transfer cases require SAE 80W or SAE 80W-90 GL-5 gear lubricant.
Full time systems use SAE 10W-30 or 10W-40 engine oil.
1981
Conventional transfer cases require DEXRON®II transmission fluid.
1982-85
All transfer cases require DEXRON®II transmission fluid.
1986-87
All transfer cases except the K30/35 series require DEXRON®II transmission fluid.

For fluid recommendations for the K30/35 transfer cases refer to the owner's manual. LEVEL CHECKS


Fig. Model 208 Transfer Case

Check the four wheel drive transfer case lubricant level every 4 months or 6,000 miles.

1. With the truck parked on a level surface and the parking brake firmly applied, remove the filler plug from the rear of the transfer case (behind the transmission). Be careful not to take out the drain plug at the bottom.
2. If lubricant trickles out, there is enough. If not, carefully insert a finger and check that the level is up to the edge of the hole, EXCEPT in full time four wheel drive cases should be 1 /2 in. below the hole.

Lubricant may be added, if necessary, with a funnel and tube, or a squeeze bulb.



DRAIN AND REFILL
Part Time Systems
No intervals are specified for changing transfer case lubricant, but it is a good idea for trucks that are worked hard or driven in deep water.

1. With the transfer case warmed up, park on a level surface and apply the parking brake.
2. Slide a pan of a least 6 pts. capacity under the case drain plug.
3. Remove the filler plug from the rear of the transfer case (behind the transmission). Remove the drain plug from the bottom.
4. Wipe the area clean and replace the drain plug.
5. Add lubricant with a suction gun or squeeze bulb. Conventional transfer cases require SAE 80W-90 GL-5 Gear Lubricant.
6. When the lubricant level is up to the bottom of the filler hole, replace the plug.

Full Time Four Wheel Drive
The full time system requires oil changes at regular intervals, according to the amount and type of work done by the unit. Trucks used for normal on-off road work should have the transfer case oil changed at 24,000 mile intervals. When used for heavy duty work, trailer towing, snowplowing, and the like, the interval should be halved to 12,000 miles. If the truck is exposed to extremely dusty or muddy conditions, the oil should be changed at 1,000 mile intervals.
The transfer case oil must be hot before changing. Drive the truck until the engine has reached normal operating temperature, and park on a level surface.

1. Slide a pan of at least 8 pts. capacity under the case drain plug.
2. Remove the filler plug.
3. Remove the lowest bolt from the front output shaft rear bearing retainer cover, and allow the lubricant to drain. Be careful; the oil will be hot. There may be a drain plug. If so, remove that instead.
4. Remove the six bolts on the left (driver's) side of the case which secure to P.T.O. (power take-off) cover. Remove this cover and allow the lubricant to drain out.
5. Remove the speedometer driven gear from the upper left rear corner of the case.
6. Use a suction gun to remove as much lubricant as possible from the case cover location and the speedometer gear location.
7. Install the speedometer driven gear, the P.T.O. cover, and the lowest bolt or drain plug.
8. Add approximately seven pints of oil through the filler plug opening. The proper oil to use is 10W-30 or 10W-40 engine oil.
9. Check the fluid level and add sufficient oil to raise the level to 1 /2 in. below the filler plug opening. Replace the plug, and wipe the surfaces of the case and skid plate to remove any excess oil. Drive the truck and check for leaks.

I really hope help ypou woth this (remember rated this help) Good luck.

Use ATF+4

Do not use Dexron or Mercon

I assume you are looking for how often maintenance is required. Every 30,000 miles or 24 monthss requires a drain and refill.

Specs: RECOMMENDED LUBRICANT AND FILL LEVEL Recommended lubricant for the NV231 transfer case is Mopart DexronII, or ATFPlus3, type7176. Approximate lubricant fill capacity is 1.2liters (2.5pints).The fill and drain plugs are both in the rear case.Correct fill level is to the bottom edge of the fill plug hole. Be sure the vehicle is level to ensure an accurate fluid level check.

You should check the transfer case fluid level. There are two plugs that require a 3/8" drive ratchet to remove. If you look closely, you may have to do some cleaning, one should be marked fill and the other should be marked drain. Remove the fill plug and use a small scrap piece of paper if no fluid comes out to dip in the hole. The fluid should be right at the top. If you can't get any fluid on a piece of paper that is about 2" long then you may have damaged the transfer case. If the fluid level is okay and the leak isn't severe(no puddles or drips in the driveway) then you may want to change the fluid, make sure there isn't excessive amounts of metal flakes in the fluid, and your whine may be a bearing, gear, or pump in the transmission.