I started having noises come from under the middle of the truck. Driving along in 2wd or 4wd high, at around 30-40 mph I started hearing a popping noise and the driveline occasionally would surge. Had a buddy ride in passenger seat with door open and figured it was the transfer case. I have searched transfer case noises and am hoping that the cause is the c-clip in the output shaft at the tailpiece. Anyone experience this have anything to chide in? Hoping that the output shaft is allowing slop in the chain and I don't have to go any deeper.

TIA

Gary

 

Well, pulled the tail cone and problem is BAAAAAD. The transfer case had 0 oil in it. I have had truck for a year and a half (50K miles) and it has never had any sign of leaking fluid of any sort except for condensate drainage from the A/C. There was no visible signs under the truck that it has ever spit any oil out as well. Guess I get to spring for a remanufactured or new tcase. Oh well its nothing but money (of which my tree in the back yard is no longer producing).

 

you can rebuild very easy with minimum tools, the cost is $575.82 allstate gear at 210-922-7901 if you need a list i will figure a way to upload a invoice. we had a 03 do the same thing, we think the oil leaks through the front seal into the coupling to the transmission so no leak spotted

 

I have almost resorted to buying a complete rebuilt unit. We broke the case apart last weekend. Bearings are toast, shafts look ok, shift forks look ok but pads on them look abused, thrust washers are toast and chain is loose as a goose. Luckily housings are in good shape with just a minimal amount of chain grinds. I found a place that would ship free of charge a rebuild with upgrades and pay for core return for $1095.00. I think I'll go that route since this would be my 1st transfer case rebuild. I used to have a jeep with an SR4 that had to be rebuilt every 10K miles because the case was machined out improperly from the factory. I was good at that one till I got rid of the original drivetrain.

Gary

 

scuzman the list has everything you listed and there is a youtube video, takes about an hour, go back with 75w-90

 

Carl, could you email me the parts list and the youtube link so I can make sure ? My email is gscales2@gmail.com.

Thanks

Gary

 

sent, take pictures as you remove parts around the sun gear, there is one part that will fit either way but if you put it in backwards it does not shift, i did not do it but others have posted they did.