Transfer case fluid change? '96 XLT

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Mike Mayer - 29 Jan 2004 00:22 GMT

Has anyone changed the transfer case fluid in a '96 XLT?

Do the tranny and transfer case share the same supply of fluid?

If not, does the transfer case take the same transmission fluid or is it
some special grade?

Easy to drain/refill?

We have 120K on the truck and I figure it couldn't hurt to change the fluid.

Thanks,

Mike

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Jim Warman - 29 Jan 2004 09:47 GMT

Your owners manual should have some of the gory details.... fluid should be
Mercon in most cases but it doesn't share the transmission fluid. This is
not to say that some years/models can't have one unit gaining fluid and the
other losing fluid......BTW, this is rarely "good".

You'll find two 3/8ths square drive plugs on the T-case. Remove the sight
plug (the upper one) first.... then remove the lower one and drain the fluid
into a suitable container. Again, the owners manual would help with
capacity, but expect 2.5 to 3 litres (one US quart is slightly less than a
litre). There is a magnet inside the case visible when the drain plug is
out...... expect some "hair" but also look for "chunks".

HTH

Jim Warman
mechanic@telusplanet.net

> Has anyone changed the transfer case fluid in a '96 XLT?
>
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>
> Mike

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Mike Mayer - 30 Jan 2004 00:39 GMT

Thanks everyone.

Reason for wanting to change the xfer case fluid is that I had been getting
the blinking 4x4/2wd/4w Low lights, which usually indicates a faulty or
dirty speed sensor. A couple months ago I removed both sensors (front and
rear), and both had metal "hair" on them (due to the magnet molded into the
Hall effect speed sensors). Cleaned the metal hair off and the 4x4 has been
fine. Past week have noticed the blinking lights again.

My assumption is that more metal hair has accumulated on the sensors, OR
that one of the sensors is actually faulty. To eliminate the metal hair
theory, I was going to change the xfer case fluid, re-clean the sensors, and
see where we go from there.

Thanks for the advice and direction.

Mike

> Your owners manual should have some of the gory details.... fluid should be
> Mercon in most cases but it doesn't share the transmission fluid. This is
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> >
> > Mike

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C. E. White - 29 Jan 2004 14:56 GMT

Ford recommends changing the transfer case fluid every 60,000 miles (normal or
severe service schedule)

The following is for a 1996 Explorer 4 WD (NOT AWD) -

Manual Transmission and Transfer Case Fluid

Checking the Manual Transmission Fluid

Clean the filler plug on the side of the case. Remove the filler plug. The fluid
level should be up to the bottom of the filler plug hole.

If additional fluid is required:

1. Add enough fluid through the filler plug hole to bring the level up to the
bottom of the hole. Use only fluid certified to meet Ford Motor Company
lubricant specification as listed under Refill Capacities, Motorcraft Parts, and
Lubricant Specifications, later in this chapter.
2. Replace the filler plug in its original position, making sure it is fully
seated.

Refill Capacities

4-Wheel Drive Transfer Case - 3.0 Pints (1.4 Liters)

Fluid Specifications

Transfer Case (4x4 Only) - Motorcraft Mercon Automatic Transmission Fluid -
XT-2-QDX - Mercon

Ed

> Has anyone changed the transfer case fluid in a '96 XLT?
>
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> Mike

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Isabelle et Pascal - 01 Feb 2004 22:16 GMT

for the tranny use:mercon v-type
for the transfercase use:mercon type automatic fluid 1.5 quarts

> Has anyone changed the transfer case fluid in a '96 XLT?
>
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>
> Mike

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