Transfer Case Empty!!!

[mtldiesel]

Morning all!!

So get this. I have a 2018 Expedition Platinum Max with Max Tow that I bought second hand almost two years ago. I have put 120,000 kms on it (75,000miles) since I bought it. It now has 175,000kms (108,000miles).
I just completed a drive across Canada and started to hear what sounded like a piece of tin flapping under the vehicle. To the point I actually pulled over to zip-tie the protective cowling up higher thinking it was hanging too low and catching the wind.
Brought it in to the dealer and after they did their diagnosis, they call to ask me if I had it serviced recently. I did not. They said the transfer case was bone dry. No signs of leaks anywhere. Both dealer and I are in complete shock and confused.
Is it possible to have driven the vehicle that long with no oil in the transfer case from the factory?

I'm at a loss and now paying for a very expressive repair. Not to mention stuck for two weeks 5000kms from home!

Any thoughts from the gurus on this forum?

Thanks!

 

[Fastcar]

Did you not check out the truck before driving across Canada? Or at least when you bought it? What was the dealer's diagnosis? You were able to drive it in.

 

[mtldiesel]

Absolutely! I bought it used from a Ford dealer as a certified pre-owned. Never had any other issues with it since I've owned except the driveline was replaced under warranty.

Truck rides and drives beautifully. Until now.

Dealer said the transfer case essentially imploded. With the lack of oil the metal ground itself up. Again zero evidence of a leak. Needs to be replaced.

Was still driving "normally" but with a constant noise above 40km/h (25 mph).

 

[Mr Big]

There would be no way the gears lasted that long. There had to be either a leak somewhere or serviced drained and not filled.
I had a situation years ago with a ford Van. Took it to a Jiffy Lube for an oil change. They had a special that day, that if you used full Synthetic, you got a free Rear End drain and filled. I opted for it. When it was all done, it made it 1 mile and the rear end started clanking. I drove back. they forgot to put the fluid back in. I had to get an entire rear axle system at their cost.

 

[mtldiesel]

There would be no way the gears lasted that long. There had to be either a leak somewhere or serviced drained and not filled.
I had a situation years ago with a ford Van. Took it to a Jiffy Lube for an oil change. They had a special that day, that if you used full Synthetic, you got a free Rear End drain and filled. I opted for it. When it was all done, it made it 1 mile and the rear end started clanking. I drove back. they forgot to put the fluid back in. I had to get an entire rear axle system at their cost.

Ouch!

I have never had it serviced for the transfer case since I've owned it. Given your experience, where could a leak be hiding that the Ford dealer is missing? Any thoughts?

 

[Rob6805]

Absolutely! I bought it used from a Ford dealer as a certified pre-owned. Never had any other issues with it since I've owned except the driveline was replaced under warranty.

Truck rides and drives beautifully. Until now.

Dealer said the transfer case essentially imploded. With the lack of oil the metal ground itself up. Again zero evidence of a leak. Needs to be replaced.

Was still driving "normally" but with a constant noise above 40km/h (25 mph).

What exactly was replaced?

 

[Soliyou]

Absolutely! I bought it used from a Ford dealer as a certified pre-owned. Never had any other issues with it since I've owned except the driveline was replaced under warranty.

Truck rides and drives beautifully. Until now.

Dealer said the transfer case essentially imploded. With the lack of oil the metal ground itself up. Again zero evidence of a leak. Needs to be replaced.

Was still driving "normally" but with a constant noise above 40km/h (25 mph).

What was replaced in the driveline service??

Just ask the dealer to put a used one from LKQ. Will cost $200-400 and there is plenty of them all over eBay and other used parts websites.

 

[mtldiesel]

What exactly was replaced?

Replaced was literally just the drive shaft. It was out of balance and was causing a vibration.

 

[Woodwolf]

Absolutely! I bought it used from a Ford dealer as a certified pre-owned. Never had any other issues with it since I've owned except the driveline was replaced under warranty.

Truck rides and drives beautifully. Until now.

Dealer said the transfer case essentially imploded. With the lack of oil the metal ground itself up. Again zero evidence of a leak. Needs to be replaced.

Was still driving "normally" but with a constant noise above 40km/h (25 mph).

Bone dry? Really? See if you can get this statement qualified at the dealer. The transfer case very well can not display any leak evidence and still loose gear oil when it gets very hot. This happens when the little breather cap/ valve gets plugged from road salt /dirt and the oil, when hot, then pushes out of the axle seals as pressures build up.
All my vehicles are modified with all the differential gear box vents extended with 1/4" hoses to the cavities high up at the rear lights or well above fenders on front. My offroad rigs like my Titan or Kawasaki Teryx have an additional fuel filter installed on the end of the vent hose to prevent dust and grime from being sucked into the gear housing when the oil cools down and the pressure equalizes. Check this out at the wheel sides. Most OEM's do a rotten job with differential case ventilation. Just want you to share on my experiences.
This is a major cause of axle seal failures in the Snow Belt and plugged breathers are overlooked.

 

[Rednecked]

Replaced was literally just the drive shaft. It was out of balance and was causing a vibration.

Another thread opened on vibrations issues. I’ve said that the driveshaft needs to rebalanced. They keep talking about tires. What do I know…. Lol

 

[Fastcar]

Bone dry? Really? See if you can get this statement qualified at the dealer. The transfer case very well can not display any leak evidence and still loose gear oil when it gets very hot. This happens when the little breather cap/ valve gets plugged from road salt /dirt and the oil, when hot, then pushes out of the axle seals as pressures build up.
All my vehicles are modified with all the differential gear box vents extended with 1/4" hoses to the cavities high up at the rear lights or well above fenders on front. My offroad rigs like my Titan or Kawasaki Teryx have an additional fuel filter installed on the end of the vent hose to prevent dust and grime from being sucked into the gear housing when the oil cools down and the pressure equalizes. Check this out at the wheel sides. Most OEM's do a rotten job with differential case ventilation. Just want you to share on my experiences.
This is a major cause of axle seal failures in the Snow Belt and plugged breathers are overlooked.

Transfer case! Not differential.

 

[Woodwolf]

Transfer case! Not differential.

I stand corrected. The transfer case venting hose/tubing is more elaborate and can also be the cause of fluid loss, as the same vent principles apply.

 

[Fastcar]

I stand corrected. The transfer case venting hose/tubing is more elaborate and can also be the cause of fluid loss, as the same vent principles apply.

I'm a bit foggy on this as my experience is old back, to the NP transfer case intro. I'd have thought that it would have trashed itself and would have become barely drivable as well as making a hell of a racket. Were it me I'd be looking for a 4X4 shop that specializes in rebuilding it. At least to get a valid or second opinion .