Transfer case noise
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Freshman User
Joined: Feb 2010
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Transfer case noise
Hey guys, today I experienced something for the first time, and it was anything but pleant. My truck's transfer case is making a noise as if it's trying to engage into 4x4. the best way I can describe it is when a newbie tries to engage 4 hi, and they pull on the lever too lightly, and find the sweet spot where things grind between 2hi and 4 hi. The truck is a stock 1997 PSD, auto, lever shift t-case. I replaced the fluid hoping it was just someone using the wrong type of fluid, and it helped, but did not totally eliminate the problem. The t-case works perfectly, and the noise is definitely coming from there. Is this a relatively easy fix, or should I leave it to the expert? I'm pretty comfortable turning wrenches, but don't feel comfortable rebuilding a t-case. My suspicion it's just something worn out on the shifter mechanism. The shifter does have about 3/4 inch play, but it engages with a positive click, and 4 low also engages nice and smooth. The grinding comes and goes, but I want to nip it in the bud, and hopefully drive this truck for years (one week, one battery, and an alyernator).
Post Fiend
Joined: Jan 2001
Posts: 5,121
Likes: 1
From: Springfield, VA
97 PSD should be the BW1356 transfer case. If it is, they are notorious for the little drive wheel for the oil pump going bad and rubbing against the chain. It makes that sound like the case is not quite engaging. It's an easy fix, but you need to pull the case, split the halves and replace the oil pump stuff. Look at this site, you need the oil pump kit (#'s 24, 25, & 26 in the drawing):
BW1356 Transfer Case Parts Illustration and parts list, you save money! - Drivetrain.com
BW1356 Transfer Case Parts Illustration and parts list, you save money! - Drivetrain.com
Post Fiend
Joined: Jan 2001
Posts: 5,121
Likes: 1
From: Springfield, VA
As long as you have the tools, then yes. The part that is rubbing is the little metal deflector that splashes oil on the chain that is pulled up from the pump. It get's bent after the lock tab on the pump (that keeps the main body from rotating) breaks off. Been there done that job twice on my 1356 case.
Post Fiend
Joined: Jan 2001
Posts: 5,121
Likes: 1
From: Springfield, VA
More than likely. It's still fairly straight forward. Here is an exploded view of your case. Just take your time, pull it apart and see what the problem is, get what you need to fix it and go from there.
Parts Diagrams
Parts Diagrams
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