RTFM (read the fawking manual). Actually the fill plig is on the back vertical side of the transfer case. It has (I believe) a 19mm head. Theres a drainplug the same size and configuration on the bottom (lowest point on the transfer case). The fill plug looks the same.
Haynes manual is actually pretty darned good. Had practically all the info I needed on my rig, and I've done alot!
The fill for the t-case is below the cone shaped plate on the back of the case. I think it is a 17mm plug, and its near the left edge of the case, by the PTO side cover. I generally put the truck on a level surface and fill until it oozes out the hole and pop the plug in quickly. Should be about 1 qt of 90 weight gear oil. Check page 131 of your Haynes, look at figure 6.57 on the top of the page. The fill plug is partly behind the dudes wrist, just up and too the left.
I have filled the T-case via the proper fill hole with a handpump and that was a major pain. Then I notice that there is a little plate on the side of T-case, and the bottom of the plate is even with the bottom of proper fill hole. I filled an empty case by taking that plate off and dumping the 90wt in a quart at a time. It took like 5 minutes. Thats how I fill an empty one now. If I just just need topping off, I still use the proper fill hole.
And for the gearbox.... pull the shifter. You can dump the 90wt right in. Much less of a pain than pumping it in.... at least for me anyway.
A forum community dedicated to custom off-road vehicle owners and enthusiasts. Come join the discussion about trail reports, builds, performance, modifications, classifieds, troubleshooting, fabrication, drivetrain, and more!