Recomended fill of transfer case
 

I have just replaced the bearings and seals in my single speed transfer case which has the enlarged base for more oil. The manual I used specifies 2 pints for single or 2 speeds. This doesn't bring the level near the fill plug. I presently have 1.5 litres in it. What does the rest of the world recommend

What truck?

oil level
 

the single speed only needs it filled to the lower fill plug, run it a bit and you will have to add a little more.

Transfer case fill
 

Sorry guys: Transfer case is in C-15 GS.

There is a service bulletin on this
 

Hi Nick

There is a service bulletin on this issue, which I'll try dig out and post. The common practice was to fill them to bottom of the filler hole this however often over fills the box and they leak.

Before I got the service bulletins I was filling my HUP according to the manual and it always leaked. Everytime it would be down an inch, then discovered that it didn't go any lower if didn't add more.

There is also a problem if you are using a pump to put the lube in, you can actually pile the lube up on the other side of the box. This is a particuler problem if the lube in when it is cold.

When filling a box that has just been rebuilt or completely drained I like to heat the lube up to 100F so I'm sure that it gets all the way in to the bearings.

Cheers Phil