Where to fill transfer case

If you want to know how here it is. Transfer cases have 2 plugs. A drain plug on the lower back of the case. And it has a fill/check plug. Remove top plug first to vent case. Remove bottom plug to drain oil. Replace bottom plug and tighten. You will need a pump or squeeze bottle to fill the case. Fill through the top hole until oil comes out of hole. Replace top plug...that's it.
Refer to owners manual for oil weight. Probably 90 but check to be sure.

1. Be sure to run your car (in 4WD) for about 5-10 minutes or so to warm the oil up and be sure to park on a level ground.First we need to gather our materials. This is what I used for my oil change:Initial expenses

• Oil Catcher - $10 at Pep Boys
• Fluid Pump - $5 at Pep Boys
• 24mm wrench or ratchet (assumed ownership)
• 12mm? and 14mm? sockets to remove skidplate

Transfer Case Change Expenses

• 3 Qt 75W90 Gear Oil - $21
• (I used Redline from myoilshop.com)

2. Locate the Transfer Case.
Remove the Fill Hole plug first, then place your oil catcher in position, and remove the drain hole plug.
While the oil drains, clean off the drain plug.

3. When finished draining, replace the drain plug, and proceed to pump the fluid into the fill hole.
I filled until the fluid overran, but you can check the fluid by sticking a pinky into the hold and checking the level.
Replace the fill hole plug, and done.

SOUNDS TO ME LIKE YOUR GEAR OIL IS LOW OR YOU HAVE THE WRONG TYPE OF GEAR OIL INSTALLED IN THE CASE, BEST TO GET IT DRAINED , FILLED WITH ATF+4 (BEST YOU CAN GET) & CHECK AGAIN, IF NOISE IS STILL PRESENT IT COULD BE THAT YOU HAVE SHEARED PLANETARY GEARS IN THE TRANSFER BOX OR IT MIGHT BE SOMETHING SIMPLER SUCH AS EXTERNAL UNIVERSAL JOINTS (UJ'S) ARE WAY ON THEIR WAY OUT, IF STILL NOISY AFTER OIL CHANGE THEN GET IT OFF THE VEHICLE & HAVE IT CHECKED OVER BY A SPECIALIST OR PICK UP A SECOND HAND UNIT FROM A BREAKERS BUT I WARN YOU IT WON'T BE CHEAP AS THERE IS A BIB MARKET FOR THESE ONCE "HAIR DRESSERS" CARS AS WHEN DONE RIGHT THERE IS NOT MUCH THAT CAN BEAT THEM OFF ROAD - I KNOW - I HAVE THREE IN SEVERAL STATES OF DIS-REPAIR & WOULDN'T PART WITH THEM FOR LOVE NOR MONEY!!!, BEST OF LUCK

To fill transfer, you didnt list the type of truck but all are about the same.
what is not the same is the type of oil used in the transfer case, its important to use the correct type. the transfer case is fill from the side, theres a drain plug at the rear bottom and then the fill is mid way up on the side of the case, you will fill until oil runs back out, allow extra oil to drain when stream is low put plug in. hope this helps.

Hi there,

CAUTION

New transfer case lubricant must be installed any time the transfer case has been submerged in water. Also, transfer case failure CAN result if the correct fill procedures are not followed.

NOTE: The transfer case is lubricated for life and is not to be checked unless a leak is suspected or a repair is necessary.

1. Remove the drain plug and drain the transfer case.
2. Apply sealant to the drain plug threads and install the plug.
3. The fluid level must be even with the bottom of the filler hole with the vehicle on flat, level ground.

To Fill:

1. Remove the fill plug and fill the transfer case with SAE 75W-140 synthetic gear lubricant.
2. Apply sealant to the fill plug and install the plug.

Cheers,


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CAPACITIES
Engine, 2WDwithout filter..........3.5 quarts[1]
Engine, 4WDwithout filter..........4.0 quarts[1]
Cooling System, Initial Fill..........8.5 quarts
AMSOIL Antifreeze and Engine Coolant
Automatic Transmission, Total Fill..........7.4 quarts
Manual Transmission, 2WD..........4.2 pints
Manual Transmission, 4WD..........8.4 pints
Differential, 2WD Rear..........3.2 pints
Differential, 4WD Rear..........2.7 pints
Differential, Front..........2.7 pints
Transfer Case,..........4.6 pints

1. Add extra oil when replacing filter.
refill check oil level.

TORQUES
Oil Drain Plug.....22-29 ft-lbs
Transfer case
Fill Plug.....18-25 ft-lbs
Drain Plug.....18-25 ft-lbs
Manual Transmission
Fill Plug.....18-25 ft-lbs
Drain Plug.....18-25 ft-lbs

I assume that by the term "transfer case", you're talking about the primary drive and transmission on your Sportster. The lubricant that you pour into the primary case also lubes the transmission. Not so on a Big Twin as they each have their own lubricants.

On the Sporty, theres a drain plug on the bottom of the primary case near the rear end of it. I'm pretty sure it uses a Torx driver to remove it. Drain the oil and refill with H-D primary & trans lube for Sportsters. Remove the derby cover at the rear of the primary cover and fill the primary until the oil level is even with the clutch pressure spring with the bike standing straight up. Replace the derby cover.

Use ATF+4

Do not use Dexron or Mercon

has your transmission oil been low? only reason i ask that is you said it acted like it was pressurized i have seen the rear seal on the trans go out and overfill the transfer case before. you never want to fill it over the fill hole. so if it held just over a quart that is what it takes. but there is still the question as to where the other fluid came from my guess would be watch for the trans fluid to be low.

No need for a diagram, to drain the oil, there's a drain plug on the bottom of the transfer box, under the handbrake drum. To fill, the fill plug is about in line with the centre of the handbrake drum and to the left. I think both plugs are 1/2" square. Fill to overflow with Texaco Multi-Gear 75W/90R. Takes about 2L or so.