The small amount (.6 litre) of oil in the transfer case is not a
good thing. Jaguar claims the unit is “sealed for life” but severe
(everyone else’s normal) service has them recommending fluid
replacement for other components. Changing the fluid in the
transfer case is hellish if you do it the way Jaguar recommends.
Fortunately I’ve installed a cheap, simple fix on my 2003 that
allows easily changing oil in the transfer case.
Fortunately the drain plug on the transfer case is a plain, old ½”
NPT (pipe thread) fitting. You need a 1 ½” pipe nipple and a ball
valve (make sure it’s OK for oil service and mine is OK for 300F).
Parts cost ~$15.
I drained the transfer case and installed the parts. I used Teflon tape suitable for oil service to assure a good seal.
To fill the case you do the following.
1.Leave the valve open
2.Install the hose fitting and route the tube up into the engine
compartment.
3.Slowly pour 550ml of fresh fluid down the tube
4.Close the valve and remove the tubing
5.Install the original drain plug and open the valve (The drain
plug has a magnet that attracts a lot of metal particles so it
needs to stay there)
The fluid I drained (after 60k km) was quite dark but looked and
smelled quite normal. But there was a teaspoon or so of metal
particles on the drain magnet and only about 300ml of fluid drained
from the case. So if the transfer case was nearly half empty after
60k km that is not a good sign. The drain procedure I use is just
what Jaguar recommends so if there was fluid in the case it should
have come out.
I used Amsoil 75W140 severe service oil for the refill. I e-
mailed Amsoil tech support and they confirmed that they meet the
applicable Ford ESE-M2C192A spec.
http://www.amsoil.com/storefront/svo.aspx

one members solution?

Jim

 

I can see an FAQ coming on, but we'll let the other members of the forum marvel at your genious!

 

Jeeez Biggie.......not me![&:]
I only found the post....lol
Nice thought though

Jim

 

Shame on you for trying to make it look like you actually did it. tsk tsk

 

What does Jag recommend? Does anyone have an electronic copy of the service manual or know where I could find one? Thanks.

 

As included in my original post....lol
I never said anythin bout doin it myself

Jim

 

I thought that member was you.

 

Nah mate.......I saw it though and thought it looked like a very plausible solution to a problem that keeps cropping up!
Got the reminder thru today.......MOT and service now due[&:]

Jim

 

Jim,

Who was it that came up with this solution? I bought the necessary parts, however there is NO WAY they will fit in the space between the transfer case and transmission. If you are able to ask this member for a picture of their setup it would be much appreciated. I have to be doing something wrong or there were some redesigns between 2003 and 2005...

 

Hey there skyjump......The member in question should be available on the link I have attached below. Be aware though, that he is from another forum, so a little intro before asking the question might be in order.
Please let me know how you get on.

Cheers

Jim
hladun@cable-lynx.net

 

Thanks Jim. I sent him an email. We'll see what he says.

 

Good luck bud............If there's anything else, just let me know.

Cheers

Jim

 

Well, I found his original post on that "other forum" along with pictures. Unfortunately, it looks like there was a major redesign in that area. My transmission is completely blocking the area he used. BUMMER!!!!

 

Sheeeeit.......thats a female dog[&:]
Whats your plans?

Jim

 

Instead of going through the hassles of draining and refilling the transfer case, why not just fill up more fluid? If it were me I would just keep filling it till it overflows then close the valve and wipe up the mess.

I saw somewhere where a guy went to a plumbing shop and got some pieces to make a valve and he tapped into the transfer case and installed a draining valve.

Anyone else read this too?

I would love to see some pics of a transfer case being filled or drained, or maybe even the step by step pictures of tapping into the transfer case.

 

Unless you want to remove the TC to fill it to the proper level,then the only other choice is the drain plug, as itis all that you can get to..

This should come up with a search for future reference

A good how to by Mr. Bojangles , esquire, mechanic extraordinaire

https://www.jaguarforums.com/m_34418/tm.htm