I just did a transfer case drain/refill. My truck has the NV241HD and I cannot find a refill quantity in my service manual, it just says fill to bottom of fill hole threads...Sitting flat and level I got just under 2 quarts in it. The counter guy I have trusted for years gave me a 3.67 pint reference, which converts to 1.87 qts so I guess I am in the ball park.
My concern is I drained out about 2.5 qts and it came out the fill plug when I removed it.....I don't remember/see why I would have overfilled it. No other issues. Fluid was dirty, but not contaminated with synchromesh as far as I could tell.....

Anything I should be concerned about?

 

In some cases the trans fluid leaks back into the transfer case.
If you lose trans fluid without visible external leaks the output shaft seal of the OD unit can be the culprit.
Overfilled transfer cases can foam up the fluid at sustained high speeds.

I'd just observe, and check the trans fluid level in exactly the same spot (I use color marks for wheel positions on my parking lot for that) to see if the above can be your problem.

 

Trans fluid WILL NOT feed from the trans to t-case.... the units are split and separately sealed + if the trans output seal leaks, it’ll drain out the weep channel.

 

Well, I had two cases where that has happened. 97 and a 98, there was no weep hole, but there were shaft seals on the output of the OD and on the input of the T-case. Both seals shot and fluid went into the transfer case.

 

Thanks for the replies. I checked it again today and it took a bit more to bring it up to the drain hole so I'm at just about 2 qts.

I'll keep my eye on it for the next couple weeks.