EVO - T-CASE FILLING

EVO T-Case Filling Procedures

It is extremely important that the transfer case in your vehicle is kept full and clean.  We recommend changing the fluid every 5-10k miles depending on the type of use and horsepower.

The recommended fluid for the Non-ACD EVO T-Case is Redline Heavyweight ShockProof (Red). For an ACD T-Case, use Mitsubishi LSD 90, Motul 90PA, or Motul 75-140 (Blue).
Make sure the O-ring seal is installed between transfer case and transmission (EVO 8/9).

There are several ways to ensure that the transfer case receives the proper amount of fluid.  Due to the design and small sump, it is very important to follow the steps below to ensure proper lubrication, quiet operation, and long life.

1. If the transfer case is new, rebuilt or out of the vehicle
   1. Tip it with the tail housing up and add 1 qt through the tail housing (where the driveshaft splines go into). 
   2. Proceed with installing the transfer case, being careful not to tip the tail housing down too far, letting the fluid run out. 
   3. After the transfer case is installed and the car is running, drive the vehicle or run it on the lift for a few miles to circulate the fluid. 
   4. The last step is to simply have the vehicle level and remove the FILL plug.  This will allow the excess fluid to run out, ensuring that all the bearings and oil passages are full, and the transfer case is at the proper level.
2. This method can be used while the transfer case fluid is being changed.  This is the messiest way but is does ensure that the transfer case is full. (May require a helper)
   1. After draining the transfer case, use a hand transfer pump and insert the hose from the end of the pump into the transfer case drain hole.
   2. Tightly wrap a rag around the hose to make a seal.
   3. Continue holding the hose while pumping 1qt into the transfer case.
   4. Quickly remove the hose and reinstall the drain plug.
   5. Now you can remove the FILL plug, letting the excess fluid run out through the fill hole.  Filling from the bottom ensures the transfer case is full.
3. This method can also be used for fluid change but has more room for error.
   1. After draining the transfer case, reinstall the drain plug.
   2. Use either a qt bottle or hand transfer pump with a hose on the end and fill the transfer case through the fill hole.
   3. Due to the design, it is very hard to know when it is full.
   4. The fill hole can push fluid back making you think it is full when it is not.
   5. If using this method, it is VERY important to let the fluid settle and try several times to refill to make absolutely certain it is full to the fill plug.

Please note that we spend a lot of time making sure bearing preloads, gear contact, and all seals are perfect and tested before your assembly leaves our facility.  We have also built a machine which can pressurize and test the ACD system for leaks and proper operation in-house.  Every part has been meticulously cleaned with high-end state-of-the-art equipment and checked.  With all of this attention to detail, the Transfer Case can be ruined easily, as the long ring and pinion contact patch is very unforgiving.  Please be sure to call (719-268-6011) us if you do not understand the fluid procedures, or if you need assistance locating required fluid.  Our goal is for your new Transfer Case to live a very long, trouble-free, life. Feel free to email us at: sales@jackstransmissions.com if you have any additional questions.