Having problems with the transfer case, started with what felt like gears missing teeth, determined it to be coming from the transfer case, upon teardown, the range selector fork was worn (plastic pads gone and worn into the metal) Replaced the fork, bearings, and seals. Everything went together good, but 500 miles later, the same problem again. I removed the PTO plate to inspect and the fork is worn again. What could be causing this, everything else inside the tcase appears to be in good condition. I have some power mods to the truck, and I regularly pull heavy loads (car hauler). the truck has 176k miles.

Any ideas / suggestions?

 

Are the pads worn on the sides or on the inside? To make things easier in the future you should fill out your sig, click on "user cp" and you can do the whole shebang. If the pads are worn on the sides, or on one side, I would suspect your linkage needs adjustment.

 

The plastic pads are gone, and the shifter fork is worn into the metal, the linkage is ok, it is on the detent. from what I can tell, the sliding collar (hi/lo selestor hub) that the fork rides on is being forced toward the neutral position, thus wearing the plastic pads, and eventually into the fork, which then causes enough play to make it jump gears. I ran it without the pto cover on to see if maybe the output shaft was bent, but everything is running true, the oil pump is working good, no visible problems to identify. I am thinking maybe the collar / input hub may be bad? Maybe it could be 176k miles, 325hp and 800 ft lbs, and it is just worn out?? looking for some suggestions so I don't keep throwing money at it..

Thanks for the help

 

There is also a Clip on the tailshaft of the transe case if you remove the tail shaft hoising it is right in front of the the bearing those are very common to break once that happens it will make a terrible racket once you here this noise the best thing to do is put the truck in 4 wheel drive and get home if you replace that clip quick enough it will not cause any damage but if you dont it will screw things up