Hey guys its been awhile since ive posted but i just got done changing the transmission filter an oil in my truck< when i pulled the pan there were to pieces on a snap ring laying in the bottom of the pan stuck to the magnet when you put them back together the way they should be its about 5 inches tip to tip so im guessing its about half of the snap ring. My question is where is it from? i didnt see anything out of the ordinary truck shifts fine. Last time the pan was off was 4/11/10 at 91,000. its is now at 108500 miles its an 04 2500 any help as to where these pieces go and how much time ive got till its gives up would be helpful thanks again guys
Dennis

 

I have read of this happening before. I think it is part of the OD clutch assembly. Can't remember exactly. Do a search.

 

Thanks spooler i did a search and i didnt find anything thanks again

 

OD clutch retainer snap ring, pretty common. If its a short chunk it is usually just a visual nuisance. If you start seeing more pieces then you have a problem.

 

Thanks a bunch i have about half of the clip the piece i have measures 5 inches tip to tip how hard of a fix is this? Cost wise an what all is involved in repairing it
thanks again dennis

 

Yeah, 5" of the snap ring is cause for concern. Unfortunately, the OD unit has to come off to replace it. Reinstall of the OD unit and clearance sis critical for OD operation so its not a simple thing.

 

that dosnt sound good everything works good now like i said its been 17000 since the pan was off last so i dont know when it happened what would you suggest is the best route to go complete rebuild with 108000 or fix what wrong? i dont tow anything at all hardly pretty much a daily driver smarty is on 60 or 90 and i dont beat on it at all slow starts always idle in neutral and let warm up for 10 minutes when its cold.
thanks again for any insight dennis

 

As mentioned earlier, it is the snap ring for the direct clutch in the OD unit. It is a pretty simple repair...I just did mine Tuesday. I, just as you was doing a trans service and found two broken pieces of snap ring in the pan. I did some searching and found it was a pretty common problem. My truck as 75k on it and last service was at 60k.

Basically just pull the transfer case off, mine was a PITA due to corrosion. After the tcase is off there are eight 11mm bolts and the OD unit slides off, trans R&R is not needed. Once on the bench remove the wire snap ring and the OD clutch pack, after this you can remove the other two snap rings at the bottom. Remove the two T25 screws for the OD bearing snap ring and remove the whole unit. You will now see the broken snap ring of the direct drive clutch. The remaining piece in the direct drive drum was broken into 3 pieces. You will need a special tool and shop press for the job as there is a spring behind the direct drive clutch with about 830 lbs.

I have a few pics that I will post when I get a chance.

 

Here is a picture of the direct clutch broken snap ring.