Hey Gents! My '03 2500 turbo diesel w/ 135K miles and auto transmission won't disengage out of 2WD into 4WD . It's always been difficult to engage between both, but would ease up after shifting back and forth numerous times. This time it's frozen and the lever into the transfer case doesn't move at all. My local garage says I probably need a different transfer case (used or rebuilt). They haven't taken it apart yet. Any idea what may have happened? Seems premature to me with relatively low miles. Does it sound repairable or am I looking at buying a replacement? Jasper wants $2267.00 for an exchange. I appreciate any thoughts you may have. Best regards!

 

It may be a little late for that transfer case but did you ever change the oil in it? Is there even oil in it?

Looking at the brackets on the front it had a snow plow mounted?

 

Well it could be quite a few things could be just the shift fork or something substantially more significant. Wont know until someone opens it up.

While I have nothing against Jasper it seems a bit steep but no idea on what current costs are or even exactly what transfer case is in that year of truck is it a 271 or 273? . On my old 01 I had to have the 241 DHD transfer case rebuilt. Now this was years ago and it was $900 and change at local transmission shop I had worked with on other vehicles. I quick search shows you can pick up a rebuilt 271 or 273 for a lot less than $2200

Also iirc as long as the case isn't cracked it should be good for the core charge

 

I'm not certain right now what if it's 271 or 273 (I've got the build sheet somewhere here at home). I'll be crawling under it today to get the numbers off the case. I've been researching and found online and via YouTube a shop in Wisconsin ( KodiakTruck.com ) I'm very impressed with at $1675 exchange. I"ve found others even cheaper but again, I believe the best choice may be dealing with Kodiak. I waas sold listening to the owner and what separates him from other overhaul shops. I'll keep you posted and thanks for your input!

 

I bought 2nd hand from a gentleman in Connecticut who only used to plow his own driveway for 3 winters (never plowed commercially). Truck only had 77K miles on it when I bought. I only used plow once in my small residential driveway. I had transfer case fluid changed to Amsoil many years ago and honestly, haven't serviced since. Didn't feel the need as I don't drive it much and it had no leaks. Probably ignorant on my part.

 

Transfer case oil is to be changed every 30,000 miles under normal service.
It might not hurt to drain what you have and change it out to see if it improves your situation any. Takes ATF4
Throw the cheap stuff in and if it frees up, then you can change to more expensive oil...
The oil is less expensive than a transfer case and is worth the gamble... You may just get lucky.

 

The transfer case I have, is shown with the picture I've attached. I'll be calling KodiakTruck.com tomorrow so see what they think.