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On my 95 F150 my transfer case quit working in any high range gears. All I have is 4lo. I'm sure my Reduction Fork the nylon pieces on the ends are broke or work out. I ordered a new fork today.
My question what other areas of weakness are there in these cases? I'm going to buy a used case complete from a wrecking yard, then tear it down & put a new fork in & if there are any other weak areas I'll install new parts there also. Then I will put it in my Ford & then rebuild that one for a spare.
see if oil is clean. got a good deal on transfer case, free! But drained oil and new i was in trouble. was dark oil. gears are worn and chain stretched. gonna rebuild! good luck! trans is rebuildable but needs some new stuff!
Another weak point on these is how the oil pump is secured. There is a little tab that keeps it from spinning, but it easily wears through the part on the case that is supposed to locate the tab. The fix is to weld a bar to the tab to hold it in place. If the pump spins around it stops sucking oil and the bearings will go.
I can't remember where I saw that, but it had pictures showing the issue and the fix.
$300 sounds like a lot for a transfer case... is this an electric one?
Thanks for the tip on the oil pump. I bought the case & had it put in today. I didn't have a bunch of choices. I was 150 miles from the nearest wrecking yards. The next closest were 300 miles away. I searched on cars-parts.com & $300 was the cheaper prices I found. The yard I bought from I have done business with in the past & their stuff has always been A-OK.
Anyway it is a done deal.
Craig