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Old 07-13-2016, 03:47 AM   #31
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Anyone reading this thread and looking for ATF check your local Ford dealership---that's right. When I did the Mark Kovalsky full flush method last year on two 4R70W's I saved just about $2.50 a quart through my close-by dealership even after a small discount I receive through NAPA. I was stunned at the price difference.

No guarantee that'll be the cheaper route but always worth a phone call.
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Old 07-13-2016, 08:17 AM   #32
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That depends on which fluid you're looking for. BTS wanted Schaefer's 204SAT. Ford dealers are unlikely to have that, but it's actually not expensive mail order, I just got unlucky with multiple shipments being packed poorly.

And yes, when you're buying 18-23 quarts (4r100 + np208), small changes in price add up.
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Old 07-13-2016, 08:15 PM   #33
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Because everything has to turn into a scavenger hunt, the shop ran into a wall figuring out the output shaft seal on the transfer case. Mind you, they were the ones that suggested replacing them to begin with.

So I started looking today at 5. I think I have the right part in hand, I'll confirm the fit tomorrow when the shop is open again. However, both the outside diameter, thickness and the number on the gasket of a timken / national 9449 seem to match what as on my np208.
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Old 07-19-2016, 12:15 AM   #34
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That was the right seal and I got the van back on Thursday.

I then worked until 3 am loading the van and getting an electronic speedo signal translator to work with the output from the transmission rather than the transfer case. Now it will shift correctly in low range. (Previously it was very confused, would not shift and would sometimes want to stay in second gear for a while after shifting back ). Yes, the speedo is now off in low range, but I'm usually not too worried about speeding when I'm in low range. Since it involved running wires to roughly the same places, I installed a transmission temperature gauge at the same time.

Finally I took the thing camping for three days starting on Friday. The transmission seems nice, and handled the 20 miles of dirt road and four miles of trail just fine. I came up Donner pass and was able to get the fluid to heat up by driving like I was asking for it. However, as soon as I backed off a little, it cooled right back down.

Watching both the new gauge (fluid temp in pan) and the scangauge (fluid temp about to exit the transmission) is interesting. As long as there's a spread, things are fine. When getting closer to 200 (which I have accepted as the top end of acceptable for a 4r100) they start to converge, which makes some sense and suggests that that's roughly where my cooling starts to break down.

Camping was wonderful. It's someone else's (legit) secret spot that I was invited to, so no trip report.

So, I'm happy with the end result.
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Old 08-30-2016, 10:31 PM   #35
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Hopefully this is finally all done now, fluid was leaking from the extension housing gasket. So I had the shop that did the install pull the transfer case back out. Here's what they found:



That's a spring lip seal, which is most certainly not on there in the correct orientation to keep fluid in. Sigh.

Nonetheless, I now have die in the transfer case so if there's any more leaking, I'll know where it's coming from.
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Old 06-14-2017, 08:43 PM   #36
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OK, hopefully the final chapter in all of this, the transfer case continued to seep. I handed to the van to a shop with real debugging skills, a week ago. They managed to figure out that that np208 won't seal correctly, against the cutout for fastening the bolts to the transmission, on the bottom of the stock Ford 4wd extension housing. This may be something to generally watch out for when mixing and matching transfer cases. That cutout is huge.

They added some material to the extension housing in that area with a welder and machined the surface flat. This seems to have resolved that leak completely.

They also replaced the slip yoke on the output side which had been seeping just a bit since I got the van. That forced a drive shaft re-balance at which point I had them do the u-joints as well. In hindsight, while I could have lived with the seeping slip yoke, the new u-joints feel wonderful compared to the old ones.

So far the van is completely dry now.

The other outcome here is that I seem to have found a shop in on the peninsula that is both willing to deal with the van (which is big and heavy) and can improvise when things go off-script due to non-factory modifications. Pricing also seemed reasonable given the amount of work involved.

Edit: The BTS transmission is doing just fine as well. In fact shifting seems to have improved after break in.
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Old 06-14-2017, 08:59 PM   #37
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Glad to hear that the issue is finely resolved and especially that you found a shop that you can trust.
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Old 06-15-2017, 02:47 PM   #38
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What is the name of the shop?
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Old 06-15-2017, 06:09 PM   #39
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wl1193: I've sent you a PM.

I'll share names publicly after more than a couple positive interactions, I don't want to have to back-pedal publicly.

Anyone else looking for a pointer, feel free to PM me.
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Old 06-17-2017, 09:58 PM   #40
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MTBike Roamer... can you PM me the name of your shop??
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