Diagnosing a bad transfer case - 2012 Expedition EL

[Pele]

Is there a temperature sensor for the transfer case? How hot should the transfer case be getting?

Had the transfer case rear (driveshaft) seal replaced and transfer case fluid changed in January a couple hundred miles ago. This was done by a reputable shop.

I needed to move a trailer out of a bit of mud, so I shifted to 4HI mode to drag it and the front wheels locked up on me.

Shifted back to 2wd mode and limped the truck home.

Crawled under and noticed the transfer case is steaming hot. I can't touch it without burning myself.

Meanwhile the transmission pan and engine oil pan, while warm, I can at least keep my hand on.

Transfer case is also making some whining/growling noises on deceleration.

2012 Expedition EL.

I'm slated to pull a 7500 lb trailer full of mulch tomorrow for my kid's Scout troop fundraiser.

What's the likelihood that the case is toast and what's the danger of running it in 2wd mode all day tomorrow?

 

[Fastcar]

Reads like it is dry. Could somebody not refilled it?

 

[Pele]

Reads like it is dry. Could somebody not refilled it?

I pulled out one quart of very thin, almost water like black fluid.

It smelled like burnt death.

 

[Fastcar]

Reads like it is dry. Could somebody not refilled it?

I pulled out one quart of very thin, almost water like black fluid.

It smelled like burnt death.

Burnt death smell most likely isn't good. I do know that when a 9" ford rear end goes south on a circle car you can smell it a mile away. Check and see what oil it calls for, then compare the two. Is there any metal or material in the drained oil? Irf not I'd try draining the rest out and refill it with whatever it calls for. Good luck!

 

[Pele]

There is no more to drain out. I have the truck parked facing up hill with the drain plugs down towards the back.

Only one quart came out.

It calls for Mercon LV, same as the transmission. That should be red.

I have literally only put 600 miles on the truck since it was serviced.

 

[Fastcar]

There is no more to drain out. I have the truck parked facing up hill with the drain plugs down towards the back.

Only one quart came out.

It calls for Mercon LV, same as the transmission. That should be red.

I have literally only put 600 miles on the truck since it was serviced.

How much does it hold? I wouldn't run it until you figure out what is going on because it sure isn't going to get better as you described it.

 

[Pele]

2.7 to 3.1 pints.

Little more than I took out.

 

[AWAR]

I wouldn’t drive it if it were mine. It needs a new transfer case. If it comes apart while driving things get expensive fast. Fuel tank, drive lines, wiring and brake lines plus it may destroy the transmission. I ran a fleet of Ford trucks and have seen all this and more.