So I was out and about this weekend and ran into another problem which I think is in my transfer case. I have the E4OD with the push button shift bw1356 as shown in the pic below (I know that it's filthy ). I noticed that I was losing transmission fluid so I bought a gasket and filter for the tranny. Well upon further inspection, I found out by drying the fluid off with some paper towels that the fluid wasn't coming out of the pan gasket. It was coming out of where the transfer case bolts to the tranny just along the back edge of the tranny pan. Well since I had the filter and gasket anyways, and it hasn't been changed, I decided to do it since I already had all the supplies. When I had it all apart I put a ratchet on the bolts that hold the transfer case to the tranny and they weren't that tight, so I snugged them up. The leak slowed down a lot, but it didn't stop. I get a drop about once every 5 minutes now (instead of around 5 drops a minute). I do want to still take this apart and fix it but i've never had any expierence with removing the transfer case. The last 4x4 I had worked flawlessly. Any body have a step by step or some pointers on how to get this apart?

Also this isn't the only problem. Yesterday while I was taking a trip out of town, I stopped at a store on my way to take the dirtbikes to the recreation area. The ground was pretty flat and when I put it into park I noticed that it rolled a little more than normal but thought nothing of it. Well when I got back into the truck and fired it up it wouldn't go anywhere. Reverse, neutral and forward didn't produce anything except some strange light clicking. When I went back to park you can hear the parking pawl try to engage and it made a lot of noise until it finally stopped. I thought that I was dead in the water. I knew that the tranny was strong and shifted good so I didn't think that was the problem. I put the truck into 4H and it didn't do anyting. I put the truck in 4L and everything locked up. I drove the remaining two miles back to where we were biking for the day. I left my manual hubs unlocked because some of the driving was on the pavement. When I got there, I put it back into 2H and everything went fine and worked like normal again. When we went to leave all seemed good till I let the truck slow down on its own (letting off the gas and the motor and tranny were draging down on the engine speed). I felt it slip again and had no power under acceleration. Luckily I was on a downhill and it locked back up right after about 15 seconds. The rest of the drive home I held a slight throttle on the engine so the drive train was always trying to go and made it home ok. It seems to me that I have a problem with the tranny output to the transfer case input or something internally wrong or out of adjustment inside the transfer case. When it's all working together, it all feels solid.

Now I haven't messed with the four wheel drive in a few months and wondered why the transfer case would be acting funny now. Is there any way to adjust the electric push button transfer case to see if that's the culprit? How hard would it be to rebuild the transfer case myself? Is there anything between the tranny and transfer case that would go bad that easily under normal driving? Would tightening the mounting bolts be the cause of my problem? I know that the case was leaking but there wasn't a visible gap between them. I would guess that it was less than 1/100". I just need to make the truck a little more dependable. Any help that you guys could give would be greatly appreciated. Thanks!


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This might sound funny but make sure the T case is full. It does take ATF! The shift forks like it when it is full.

 

LOL. I know that. I haven't gotten the time to get under there and check it yet. I'm thinking that the leak that I had might of been out of the transfer case and caused it to run low. I might have to pull it out and tear it apart. Is this a hard rebuild to do?