Dana 20 Fluid level

I looked in my Haynes Manual and it states in there that the Dana 20 transfer case takes 3.25 pints of gear oil. Is this correct???? I ask because when I was changing the oil out as soon as I took the plug out it started oozzing out. And it wasn't pretty. Looked a little like Chocolate milk. I know that can't be good. So I put about 3.5 pints in it and it isn't even close to being up to the plug. How are you supposed to check level if you can't get your finger to it???????

Help me out.........again

High5:stout:

 

Are you on level ground? When on level ground it won’t hurt to fill the tranny until it just starts to come out the fill hole IMO.

Edit:Just wondering, how do you know it’s not even close to fill if you can’t check with your finger?

 

I have always heard to fill it up until it oozes out of the fill hole. I know about the chocolate milk problem. Sounds like you got water into it at some point.

After 1000 miles (since complete rebuild) I pulled my t-case to swap in tera-low gears. The lube was black and not pretty. It smelled ok and was not gritty when rubbed between my fingers. Of course, of that 1000 miles, about 90% of it has been locked in 4wd.

 

If water got in, it could mix with the oil and increase the volume. Since it's milky, I'd suggest you change the oil a couple of times in both the transfer case and transmission. Oil will transfer back and forth through the bearings, so if one is contaminated, so is the other.

 

Yeah, I emptied both of them the other night. The T 18 looked decent, more just black. Transfer case on the other hand was that milky brown color. I found it interesting that as soon as the cap came off the Dana 20 it started pouring out. I mean pouring, not oozzing. That's when I decided to drain and replace fluids. That and I am chasing rattle gremlins and wondered if my transfer case or trans took a crap on me. I found no small pieces floating around so that is good. I am pretty sure my steering shaft is rattling against the exhaust and that is why I am hearing it underneath the ride. Still haven't found a bearing to fit the lower column. Any help there?????

So you all think I should fill until it comes out??? I am on level ground, or close. Why would the Haynes say 3.25 pints???

High5:stout:

 

where is the location of your fill plug ?
on the back or on the side ?
I seem to recall they raised the fill plug on later D20s
and I think your plug is on the rear
disregard the side comment,D18

 

FYI
my 72 Jeep manual states 3.25 pints

 

On second thought, I recall something about a rear seal on the T18, so gear oil may not transfer. The Borg-Warner 3-speeds all share oil between the transmission and transfer case.

 

Tim that's correct
there is a seal in the adapter which keeps the 2 oils seperated.
so I suppose if the T18 were extremely low, and the D20 was grossly overfull, that would indicate the seal is bad.

 

Well, that T 18 is sharing fluid with somethin' Seems like it's more sharing with the bottom side of the Jeep though I just keep adding since it shifts well and doesn't make too much noise unless I'm in first. I think that must be normal since it has done that since day 1. Has anyone else had problems with their steering column lowering bearing wearing out and the shaft rattling against the header???? Or is it just me???

Thanks

High5:stout: