Transfer Case So Hot IT MELTED SHIFT BOOT!!!!!! WHY ME? - Ford Powerstroke Diesel Forum
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Old 05-08-2010, 09:08 AM
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Transfer Case So Hot IT MELTED SHIFT BOOT!!!!!! WHY ME?

Travelling home from a job the other day towing a 4,000 lb traile (no big deal) and after 70 or so miles could tell something was getting hot but coolant and trans. temps were fine. Finally pulled off when smoked started coming up from floor. Found that rubber boot around tranfer case shifter was melting. Transfer case was vey hot (enough to burn me.) Hubs were unlocked (verified this by noting front driveshaft spins free) and transfer case was shifted into 2-wheel. Any ideas what caused this extreme heat up????? I had used it in 4-wheel that day - could the transfer case have got stuck in 4-wheel and the long highway miles towing a trailer caused this major overheat???? Do you think my transfer case is toast? Anyone with ideas would be appreciated.
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Old 05-08-2010, 09:10 AM
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Sorry for the typos.

Typing too fast. Just pissed off.
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Old 05-08-2010, 09:17 AM
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I would recommend changing the fluid no matter what. You can also check to see if there is any particulate in the oil while you do this. I always reverse 5 or so feet after I take it out of 4wd and unlock the hubs just to allow everything to release. I dunno if its necessary for our trucks but I HAD to do it on my old mud truck so its just habit now....
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Old 05-08-2010, 09:35 AM
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Will change fluid.

I am for sure going to change fluid if the damn thing still works. Gotta put it in 4-wheel and see but anyone with any ideas why?
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Old 05-08-2010, 07:15 PM
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Check the stupid (easy) stuff first. If it is low on fluid, I don't blame it for overheating...
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Old 05-09-2010, 04:07 AM
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Should have said that I already checked fluid and it was just below fill hole so pretty much ok. Thanks anyway.
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Old 05-09-2010, 09:42 AM
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Only issue I have with this is that the boot is ahead of the transfer case about a foot. I have not seen or heard of any issues with transfer cases overheating. I'm not saying that it didn't happen, but I would be looking at the trans more that the transfer case.
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Old 08-02-2010, 01:31 PM
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I've gone through 2 T Cases on this truck and its a pain to find non destroyed rebuilt unit
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Old 08-02-2010, 01:37 PM
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I've gone through 2 T Cases on this truck and its a pain to find non destroyed rebuilt unit
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