Transfer case replacement screwup

[VirginiaHeritage]

I had my Advanced 4WD transfer case replaced under warranty at just over 13k. The dealer claimed the low speed hum noise I had been hearing came from there. That was about 4k miles ago.

Yesterday we had a couple occurrences of burnt rubber smell at stoplights but it didn’t persist. While rolling around under the Bronco this morning to check things out, I noticed a wiring harness on the front of the transfer case looked oily. The fluid was flowing down the wire protector from higher up and it was reddish. I traced it to an area thats hard to see closer to the top of the front of the transfer case and found a hose disconnected with the clamp pushed way up the hose. See pic below. I had already wiped some fluid off the harness when I took these.

I’m guessing this is a breather tube for the t-case case and it never got reconnected after the t-case was replaced. Again, that was 4k miles ago.

I haven’t had drip marks in my garage and don’t think a lot of fluid was lost, but my concern is that water or other contaminants got in through that port. Especially with recent thorough underbody rinses I’ve done to get off road chemicals.

I’m thinking I should ask for a free transfer case fluid change at minimum to make sure the level is good and clean. Looking for input or other suggestions. Expert advice from @Ducati1098 especially.

Harness at front of t-case:

Circled in red is the naked hose barb above the harness:

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[Ducati1098]

Yeah just a vent hose. Really no big deal, but I would certainly have them at least check the fluid level.

 

[VirginiaHeritage]

Yeah just a vent hose. Really no big deal, but I would certainly have them at least check the fluid level.

Thanks! How flammable is that fluid and should I be concerned about the harness being soaked in it? It was flowing down the wires.

 

[crenca]

My OCD would have me changing the tcase fluid myself given the vigorous under body rinses you’ve done. It’s easy, maybe easier then you getting under there for those pics

 

[VirginiaHeritage]

My OCD would have me changing the tcase fluid myself given the vigorous under body rinses you’ve done. It’s easy, maybe easier then you getting under there for those pics

I swear it was easier to roll around under there on the dolly this summer. Either the truck sits slightly lower now or my belly is fatter.

 

[Ducati1098]

Thanks! How flammable is that fluid and should I be concerned about the harness being soaked in it? It was flowing down the wires.

Not easily flammable, nothing I would worry about.
The wires will be fine, I would just clean everything off the best you can. Or have them do it.

 

[VirginiaHeritage]

Resolution: The dealer connected the tube properly, cleaned the harness, and did a transfer case fluid change for me at no charge.

I checked the indexing of the fill & drain nuts to confirm they were actually removed. All good now, I suppose.

 

[crenca]

Resolution: The dealer connected the tube properly, cleaned the harness, and did a transfer case fluid change for me at no charge.

I checked the indexing of the fill & drain nuts to confirm they were actually removed. All good now, I suppose.

I can't think of anything more to do, short of tearing it down for an inspection which would be overkill.

 

[redone17]

Resolution: The dealer connected the tube properly, cleaned the harness, and did a transfer case fluid change for me at no charge.

I checked the indexing of the fill & drain nuts to confirm they were actually removed. All good now, I suppose.

I can’t imagine they took a drainage measurement - but, did you ask?

 

[ssls6]

I would connect the vent line with clamp (maybe you need one). Spray out the connector and surrounding area with brake clean. Put a little dielectric on the outside of the male part of the connector plug and reconnect. Remove the fill plug and refill till it to the threads. Watch for future leaks and then go to the dealer if needed. That's just me.

 

[VirginiaHeritage]

I can’t imagine they took a drainage measurement - but, did you ask?

Didn’t think of it. Never saw drips in my garage so I don’t think it was a significant loss.

 

[VirginiaHeritage]

I would connect the vent line with clamp (maybe you need one). Spray out the connector and surrounding area with brake clean. Put a little dielectric on the outside of the male part of the connector plug and reconnect. Remove the fill plug and refill till it to the threads. Watch for future leaks and then go to the dealer if needed. That's just me.

There is a clamp. It was a couple of inches up the tube from the original clamp indentation and theres no way it slipped up there. They forgot it when they put the new t-case in. I wanted them to handle this so it’s documented in case I need another free transfer case down the line.

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