I just got back from a buffalo hunt in the Henry Mtns in Southern Utah. While I was hauling horses I got stuck in a sand bar and threw the truck in 4 high. The truck started making a popping/clanking sound everytime I would turn the wheel. I took the front diff off tonight and all the gears look good. I also checked the ball joints and they seem fine. I did need to put a quart of ATF in the transfer case and I hope this is not the problem. Has anyone out there had to replace their transfer case, and how much was it? I heard you don't want that to go out. My wife did harvest an awesome bull down there so that takes a little bit of the sting out of fixing my truck. Just a little bit though.

 

A quart sounds like a lot. You sure you didn't overfill? I think it's about 2.5 qts for the transfer case. Time for me to change my fluid at 60K.

 

it should be 2.3 quarts but when I changed ine a a few weeks ago it took around 2.75 quarts

 

I had two transfer cases go on me under warranty. The both were replaced for $100 a piece deductible.

After finally talking to a transmission guy on another site he told me to check the yoke seal and yoke to see if it was cracked or the seal was letting fluid seep by.

After checking it the seal had a leak and got it fixed for $30 and no problems since. Been about yr since that.

 

I recently had a leak under my 03. It turned out that the tranfer case output seal was worn, allowing the fluid to leak past the seal. The dealer replaced it under my extended warranty.