Can I do my transfer case rebuild in the truck? I don't think I need a complete rebuild, but maybe a chain and a shift fork, as it pops out of gear in 4 lo, when shifting between reverse and Drive, causing the great grinding noise, and silently slips out of 4 hi to 2 hi when just driving, within 200 feet of putting in 4 hi.
It sure would be nice if I could just break the case apart under the truck, put in the necessary parts and put the case back together.
Nothing really leaks from it, and I have no idea if I actually need a chain, as I have not pulled it apart yet.
Would I need the shift fork or "mode" fork, or both? From what I have read, it seems there are both type forks in there.

Thanks,
Chris

 

I would recommend pulling the case out of the truck. They aren't that heavy and they are really easy to get off. the hardest part is the nut on the very top of the case and that isn't terrible. You sahould be able to get it done in a day depending on parts availability. I'm afraid when you go to put the case back together in the truck you won't be able to get the thing sealed back up.

 

It probabaly would be more work to do the rebuild in the truck rather that take it out. Just make sure you have a friend help you take it out and put back in. They are heavy enough not to do it your self.

 

hmmmmm! I did two myself. They aren't light but they are aluminum. You might want a friend. that would help quite a bit.

 

Im not saying its impossible to do yourself...in fact I've done it before, but its not very smart. It wouldn't take much to drop it and damage either yourself or the case.

 

I would definitely pull the case, pulled it on my '99 a couple times as well as a friends F250 just last weekend. Both cases I removed and installed by hand myself, not that big of a deal. it'll make you grunt a little. Not sure what it weighs exactly but definitely doable.

I would say it is not worth it to try to do in the truck.

 

You cannot get the chain off without pulling the main shaft back a little so you can get the front wheel drive back far enough to disengage the chain would be a hell of a job in the truck

 

OK, so I pull it out. Now, with the problems I described, what parts should I have on hand before I get started? I can't let this truck sit around for a week as it is the work truck. Also, it won't fit completely in the garage, so if I can't get it done in a day I have to push it outside. I'm debating the entire kit or just the parts I may need. As I said, I figure the shift fork, and/or the "mode" fork, possibly a chain, and maybe the case gasket. I understand the some of these cases have replaceable guides so I won;t even have to replace the entire shift fork if I have one of those. I'll figure that out by the number on the tag, I suppose.
Where's the best place to get the parts?

Thanks,
Chris

 

National Drive Train in Chicago I just bought the range shift fork and 2 nylon pad kits very reasonable.