Interesting that the capacity listed is 3.9 pints but actual quantity to top off is right at around 3.9 quarts! Coincidence? Also interesting that you pull out only 2 quarts from factory fill which is 3.9 pints. Could this be a factory worker filling the fluid to "spec" versus to bottom of fill hole, and could it be a typo that they said pints when it should be quart?
If all of this speculation is true, could 4x4 libbys be at risk right out of factory?
There is a very good chance that the chain in my transfer case is stretched and that's the cause of my vibration. I'll know more after tomorrow if the new trutrac doesn't fix it. I had the same problem with the capacity issue, also with the diffs. The manual was almost a quart off for the front diff. Seems to me that the factory was cutting corners. I know for a fact that they build their cars based on 100,000 miles. They pay close attention to every step in the production process and save pennies whenever they can. I wouldn't trust the writes capacity when it contradicts the procedure, especially if it's on the short side. I'm driving around with 3 quarts for the moment but intend to top it off when I get a chance.
Perhaps the final note: filled up to bottom of fill hole and tcase did a "purge" of the excess. Just fill to spec amount rather than to bottom of fill hole. Must have an overpressure relief valve on it.
I topped mine off shortly after my last post. I noticed the front seal is seeping fluid. Not sure if it's related to the problems I'm having with the front axle but it's not likely. Maybe these aren't supposed to be filled all the way. If that's the case though, how does one check the fluid level?
The tricky part is how much do you put in. The spec amount or fill to bottom of fill hole as the manual says both, but the amount isn't close to the same. The answer is to fill it to the spec amount instead. Filling to bottom of fill hole is too much.
Haha, you will not blow out seals with too much oil in any engine, transnfr case, or diff. The proper procedure for any transfer case, diff, or manual trans is to fill it until the fluid starts to drip out the fill hole. Even if you coukd stuff 8 quarts in the transfer case, the seals wont "blow out". The only was a seal can blow out is if theres pressure behind it, which there is not present at tge seals in drivetrain parts, un0less you drive a hydraulic powere drivetrained vehicle like a crop fertilizer tractor. Yes, the seals may leak but thats not from more pressure from extra oil. The front output seal on the transfer case and pinion seal on the diffs are under the fluid levels and seal the oil in. Old seals above the oil level may be hardened and weak/cracked which will seep oil if the level is above their level. Pressure is made by pumps, not by oil level. Its not a good idea to overfill engines or automatic trans due to oil aeration, which will kill bearings and sliding surfaces. Even if you overfill the rest it wont really gurt anything, may make a mess if it gets puked out tge vent tubes and past seals not made for being immersed in oil. Follow the recomended procedure to fill to the fill hole, thats the proper level. Even if its a pint and a half more than recomended, its still how the engineers designed it to be filled. That little bit extra, if it is too much, will not blow seals or harm anything. Id rather have a little more than recomended than be under. Oil is also used to cool parts, less oil means less cooling. Not to mention the high speed driving will cause tge oil to be flung away from moving parts, making less available in the sump to lubricate the gears, bearings, and chain. There is a pump in the case that uses oil to feed the bearings, especially the ones above the oil level. Anyway, fill the gluid level until the fluid runs out tge fill hole. It will be at the proper level for that part as the engineers designed it. Someone messed up on the spec sheet at the printing place or the guy writing the manuals was drunk that day. All sources use the specs the manufacturer gives, so if Mopar says its a certain number thats what all sources will state, even if its wrong. Clymer, Haynes, etc go by what Jeep says. Best way would be to contact tge actual company tgat nade tge transfer case and ask them, which is probably New Process, which Dodge used for their trucks and suv models.