Well, I have finally completed my easy transfer case (TC)
fluid change and am pleased to say that it works.
First, let me give credit to Anthony Hladun and all those
others who have done this in various manners before. I want
to acknowledge that I used all your good work as a
foundation for my method.
What I wanted to do was to come up with a method and
associated hardware that would be easy enough to do so that
I could change it as often as I wanted to and I needed to be
able to do it on an automatic transmission car where the
space is very tight. I also wanted to avoid cobbling
together bits and pieces if possible.
The solution I came up with was a one-way valve to replace
the drain plug and a pump that would meter the fluid you
pumped in.
The valve I had made is shown in the pictures below. The
valve body is high carbon steel with male pipe threads to
allow it to screw into the transfer case in place of the
drain plug. The valve body and gate or plunger are carbon
steel, the spring is stainless steel, and the seal is Dupont
Viton rated for use with petroleum products. The cracking
pressure on the valve is only .125 PSI and the length of the
valve is 1.3’’. I chose this length so that the open end of
the valve is slightly recessed into the pocket of the TC
when the valve is snugged into place. (See picture #6 below)
In addition, I fashioned a 90 degree elbow with a short male
nipple so that I could thread it into the valve in the small
space available in automatic transmission cars and purchased
a 2’’ nipple and reducer that screw into the elbow, a
magnetic drain plug to fit the female (open) end of the
valve, a roll of petroleum specific Teflon sealing tape, and
a CRC hand pump that delivers 1 fl. oz. per stroke.
Here’s what I did (see pictures below).
- Remove the drain plug (My TC was dry!!!)
- Install the valve with Teflon tape sealant specific to
petroleum applications - Install the elbow loosely (two turns was sufficient)
- Install the reducer and nipple loosely
- Slide the flexible plastic hose from the pump over the
nipple - Pump 400 ml (13 strokes) of approved gear lube into the TC
- Remove the pump, nipple, and elbow leaving the gate
valve to hold the fluid in the TC - Install the magnetic plug into the female end of the
valve to protect it from the elements and to serve as a
back-up seal.
I pumped in 400 ml because that is the amount you can drain
from a correctly filled TC using the drain plug. I am
attempting to source the valve with a magnetic gate but do
know if that will be possible. The valve I had made cost me
over $50.00 as is but buying in small quantities may lower
the price. All in I have ~$100.00 into the system using
one-off sourcing without the gear lube. I am exploring
sourcing small quantities and offering all the parts with
detailed instructions as kits. The installed product looks
quite professional IMHO.
http://www.jag-lovers.org/snaps/snap_view.php3?id=1226853201&n4=--
Wild Bill
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