Transfer Box
 

I went to check the level of oil in the Transfer Box and I can't get the Filler/level plug off. It seems the dealership might have checked to fluid level last time I took it in for warranty work. Anyways the plug won't budge and I can't get a cheater bar for more leverage because there is a wire (connected right next to the filler plug) is in the way. Do you guys have any suggestions on how I can loosen the plug? The wire appears to be a sensor. (I am not sure what it is maybe high low sensor.) The tech manual shows a picture of it but I can not find a name for it. It has the diameter of a quarter and is connected on the top part of the transfer box.

Do you have a D1? On a D1 all that is needed to remove the transfer case fill plug is a 1/2" ratchet. The wires back there are for the vehicle speed sensor. I can't imagine that it would be that difficult to remove the plug since it is kind of bathed in gear oil. Maybe its cross-threaded.

I assume that everything is the same on a D2, since they have the LT230.

It’s a D2. I tried to use a half inch ratchet. (It appears the dealership really cranked the plug on.) How does the speed sensor come off? Does it pull off? That was another question I had. ( I am afraid if I try to crank on the ratchet I might slip and damage a wire.

http://68.49.91.161/vss/index.htm. That tech article describes how to remove the VSS. Should be the same on a D2.

Its not the speed senor wire that is giving me problems, unless it looks different on Disco 2. Its a wire about the diameter of a pencil wraped in insulation, (with insulation diameter of quater) and is connected the transfer box. Could this be the high/low sensor?

I got the nut off. I went to Merchants tire and they put it on a lift. The mechanic and I got a long adjustable wrench and pulled it until it came loose. I checked it and the oil level was OK.

Now I just need to find an easier way to add extra oil without wearing most of it.

Long adjustable wrench? That sounds interesting. The T-case filler hole is definitely a square 1/2" ratchet. No need for a wrench. If anything just use a breaker bar with the ratchet, but it is usually not on that tight. Sounds like a previous owner took some liberties with that filler bolt.

It is further interesting that you got gear oil all over you. If the rig was level you should have been fine. When filling a little might drip out, but this is not an overly wet process.

Also - keep in mind that unless you have some visible leaks somewhere you will not lose gear oil in the T-case. Even most visible leaks do not amount to much actual loss. The T-case is best checked with a pinky finger in the filler hole between fluid replacement.

It was the dealership. I took it in to have the gear box gasket replaced and they must have checked the transferbox fluid. The dealership has a tendency to over tighten stuff. It got to the point when I would get the warranty work done I would insist they would not change the oil. (They would put oil filter on so tight that it would take me the longest time to get it off. The same thing occured with the oil drain plug.)

Anyone have any good suggestions for oil hand pumps to pump oil to the transfer box. I have been meaning to do this and it would make life easier.

check the tools and technique forum, and look for the thread that read something like "tired of getting slimmed" or something like that. They have a bucket pump.
sam

I bought one of those cheap-o thumb-pumps that screw onto the top of the gear-lube bottle. You can find these at almost any parts store. Kinda slow, but not messy.

I bought a little hand pump and some 80/90 Lucas High Preformance gear oil yesturday. It was a little slow but everything went without a hitch. Thanks for the help.