t-case issue
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Joined: Jan 2009
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From: Didsbury Alberta Canada
t-case issue
History: last winter while shifting into 4hi I noticed a clunking sound every time I went into 4 hi ~if it would actually get into 4hi. Took it to a dealer they said it was the front driveshaft so I had them replace it. Now I take it in for my 100k service (actually im at 104k, couldn't get in until now, my fault not theirs) and when they were draining the tcase oil they find some teflon coated plastic pieces (blue in color if it helps) which I presume could be from a number of different things -I'm thinking shift fork gear. By the way they say since it is over 100k I'm out of powertrain warranty so I have to foot the bill and because I never reported a problem after the driveshaft fix I can't attribute this to the cause of the earlier problem, do you think I should let them dismantel it or take it to a tranny shop that specializes in this sort of thing? Any ideas of what this could be or the potential hazards I could face if I leave it be?
Cargo Master
Joined: Nov 2004
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From: So Oregon
Is it a daily driver? If not, I'd tackle it myself. If you're mechanically inclined it's not a huge job to take the transfer case apart. I wish I could better remember what the inside looks like, but it's been a while. It didn't leak though? I'm wondering about a chain tensioner or something...
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From: Didsbury Alberta Canada
It is a daily driver (work truck) so I don't think I have the time (although I think I could do the work) I've rebuilt 3 4x4's ( 1 jeep and 2 raiders) and used to restore antique cars about 5 of them part time. I don't have a photo of the pieces but they were about the thickness of a dime, semilunar in shape (half moon shape) and an inch or so long but to me it seem as though they came from the face of a gear or something, the bottom (inside of the half circle) seem to be flattened(squished) or sheared. It's tough I've got my trailer on site and I have to decide if I should have the work done now before I need to move it or risk the truck sitting in the shop and rent a truck to move my trailer should that be necessary.
Anyway Thanks for the replies.
Anyway Thanks for the replies.
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From: Didsbury Alberta Canada
yes it is - don't know how that affects the situation inside the t case but if you know something I don't Please let me know
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Fleet Mechanic
Joined: Apr 2007
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From: NH
You didn't mention if you still notice any problems with it. If it works fine and doesn't exhibit any problems i would leave it alone for now unless you want to spend the cash for a piece of mind.
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New User
Joined: Jan 2009
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From: Didsbury Alberta Canada
I don't really notice any problem I guess getting in and out of 4x4 is a little more difficult than other vehicles i've had ie.) dodge. What scares me is the ford mechanic basically said if I don't have it diagnosed the whole thing could just explode.
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Joined: Jul 2002
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From: Long Island USA
There is also NO chain tensioner.
Cargo Master
Joined: Nov 2004
Posts: 2,751
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From: So Oregon
Yep, you're right, I mentioned the chain tensioner as an idea, but now that I think about it there isn't one...that's why if the chain stretches it needs to be replaced (not that it happens, or often). The only things I remember seeing in one is gaskets, not half moon shaped plastic deals. I'm at a loss, but I'd like to know.
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From: Didsbury Alberta Canada
the teflon pads on the end of the shift forks sound like the culprit, i'm sure their function is to smooth shifting. Do you think these pads are critical, the shop rate here is $109/hour so I figured 2 hours to get t case out - 2 hours to diagnose - 1 hour to change part - 2 hours to get it back together, that's $800.00 labour not including parts.They Service guy figured it would be around $1200.00 total. What do you think? I chose to wait until late next week to take the truck in, but I'll let you know what exactly the problem was.
Cargo Master
Joined: Nov 2004
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From: So Oregon
Eight to twelve hours seems reasonable. They could do it faster if they've done it a couple times before, but I wouldn't expect a dealership shop to do it any faster, they've gotta take lunch breaks and all 
Do they have to remove the case, or would they have access to the parts by removing just the back half? I don't know that one way is better than the other if you've got all the space, a lift and the tools.
Do they have to remove the case, or would they have access to the parts by removing just the back half? I don't know that one way is better than the other if you've got all the space, a lift and the tools.
FTE Leadership Emeritus
Joined: Jul 2002
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From: Long Island USA
For $1200, couldn't you find a junkyard transfer case and do the swap yourself?
Then, take apart the old one, figure out what went wrong on your own time, fix it and keep it for a spare?
Then, take apart the old one, figure out what went wrong on your own time, fix it and keep it for a spare?