Well I've a new chain, plastic tips for the engagement fork, and gaskets/seals. It in a my 06 with a 6-speed. Any one replace there own chain before? Looking for tips, hidden snap rings, etc. Any special tools? I've got a well stocked tool box, lift, etc. It took me 3 1/2 hours to replace my clutch last spring, that was easyer than R&R the clutch in my hemi GTX. Planing on tackling it Wednesday night. Thanks in advance.

 

I have been looking for this too. Please keep us posted on what you find. I need to pull mine apart for a vibration. How did you know to replace your chain?

 

I'd recomend you take the case out of the truck. I've done it both ways and it's worth the extra effort to repair it on the bench.

Make sure you buy all three plastic pads for the shift fork, not just the two for the tips. It they have worn out they will have damaged the drum that they push so you might as well order that as well.

Order the three snap rings. There is one on the output shaft and one on each of the chain sprockets. I've always struggled to get these off with damaging them, nothing worse than waiting for a part you should have ordered!

A you might as well put a new oil pump in while you are there....cheap insurance!

 

Thanks guys, your a lot of help.

 

Post some pics. We have a lot of DIY people and not often does a rebuilt transfer case get wrote up and documented.

 

Did my tranfercase today. Start to finish took around 4 hours. Just under $180 in parts. The chain was shot, very sloppy, it was hitting the case. Sorry no pics. It was cake walk, the hardest part was get the case apart. Thanks again. I shopped around for parts. Found the the local dealer was the cheapest. The chain was $94, rear yoke seal $34, snap rings around $1.60 each, and of course the fluid.

 

Just curious. How many miles were on it and what kind of use did it see?

 

It has 89430 miles on it. Lots of hwy driving, no off roading. I do use 4wd in the snow around town. As far as towing, light open deck 18ft car trailer, and a 32ft enclosed car trailer. Maybe 30K of those miles are towing. I would of replaced the oil pump in it, but my local dealers parts guy told me that there was no such animal. He was wrong, there is a oil pump. I got a exploded diagram from him along with part numbers, the oil pump was going to be a week out, I didn't want to wait that much longer and with what I found I'm glad I didn't.