I know a made a similar post about a month ago, but I have a problem with my T-Case, and I am going to need 4x4 in a short period, so it is time to fix it. In 2x4, no problems nothing at all, but in 4x4, under a load or a hard accel, there is a grinding sound coming from my transfer case and it shakes violently. The front wheels still spin, but it grinds. IN 4x4 while idling, nothing, but while in 4 low, it is a low enough gear to put a load on it and it immediately starts to grind.
Any ideas on what this could be? I know very little about transfer cases. WOuld a reputable transmission shop be the place to take it for diagnostics and repair/rebuild? I found a few on ebay and in junk yards from $600-$900, so is it worth buying a new one or rebuilding mine? Thanks.

MSandt

 

The Transfercase on the 04 that I had did the same thing you are discribing. In my case the transfercase was out of oil, and it was cheaper to get a new one then to fix it.
Their is a Transfercase advertised in the 3rd gen classifieds might to worth checking out.

 

Told and read many times that the tranfer cases are easy to fix for the most part.Told they are simple.Think I'd look into that one first if possable.Get a tech that has done this type of work and ask him to let you be their at teardown or ask a gearhead buddy to open it with you.

 

Hound Dog-
Do you know what the problem was with othes' transfer cases? Thanks.

MSandt

 

Loose chains and worn gears/worn shift forks and collars for the most part.Do a SEARCH on some of these sites.See if any REAL 4x4 shops near you and pick someones brain thats been into many transfer cases.The gear to gear units I've heard are a bit more difficult but the chain drive units are so called simple to repair unless case damage etc.

 

Thanks, I'm gonna look around and talk to some 4x4 and trannsmission shops aorund here and see what they say. Ive done lots of searching, just never found anything solid. I have seen that the transfer case has been a pretty common problem with others on 03 and 04 trucks around my mileage. Thanks again.

MSandt

 

A good transmission shop will do the job as well. The chain drives are easy to rebuild, but the grinding can be a sign of case involvment, then it gets expensive. The gear to gear units do require a bit more technical knowledge, but I believe in both types the shaft breakdown and setup requires a jig fixture? I have yet to tear into a Dodge case, but in the Fords they were fairly easy to rebuild.

CD

 

I suspect most are like mine, which fried at about 60k miles. The oil slowly seeps out the *center* of the slip yoke that is attached to the driveshaft on the 03/04 models. Not sure if/how that was addressed on newer models, but it was obvious that the slow "leak" relieved it of its fluid. In my case the dealer rebuilt the tcase and it was $50 less than the cutoff $ for ordering a new one so they had to rebuild it. It's been fine since, but they never addressed the cause of it, that driveshaft yoke with the leak. Stupid. It still leaks to this day, the underside of my truck is covered with a mysterious oil/dust mix that isn't quite wet but not quite dry either.

Andy

 

So chances are it is best to buy a new tcase than to rebuild the old. I am still going to check it out, as far as rebuilding it, but I am thinking it is going to be cheaper to buy one out of a scrap yard or something and replace it. I now know the cause, I too have the mysterous oil covering the underside. I thought it was the tranny oil, and checked it often, and it was good, so I assumed I was ok. Turns out, it was ATF+4, just out of my tcase like realsquash said. Cus when it first started acting up, I checked the fluid level and it was low in the transfer case. Dang the luck. Thanks guys.

MSandt

 

Don't let the *********** people tell you it's the output shaft seal, because it's not! It's going *through* the yoke and coming out behind the ujoint!

Andy

 

I still have a manual T-case if interested.

 

mjsandt realsquash what have you guys done to fix this problem? was it a seal?? i am having the same problem. just started yesterday. how much are you guys leaking and over what amount of time. just wondering how big a problem this is. want to get it fixed asap but need to drive until then. no warranty.

 

Did you take the "fill hole" plug off and check the oil level?

Do that first. If its low, then drain it and re-fill and see of the grinding noise goes away. I don't think so at this point, but worth a shot.

Good luck.