Transfer Case issues/questions
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Junior User
Joined: Aug 2009
Posts: 80
Likes: 0
From: nola,NC, cali
Transfer Case issues/questions
Ok, it's been a while since I posted and it has been an epoch battle against this truck just to get it to stay on the road for more than 1k miles. The latest major headache happened driving on a long trip where at the end of 500 miles straight on the interstate I exited and as soon as I got to the first stop light the transmision refused to go into any gears. I have the 6 speed with 4x4 and it would click in like it was going in to gear but when I let the clutch off it doesn't bite on anything. I was able to limp it to a shop by using only the 4 wheel Low whihc is what made me think it's not the trannny. When in 4L it goes into every gear it just fine but will do nothing in 4H and 2H. The shop only road tested it and quoted me for a new tranny, transfer case and labor to the tune of about 6k. Last night I went to grab the transfer case off of my donor truck at which point I noticed it has fluid all over it and after taking the plug out there was only a couple ounces of oil with some glitter sized shavings in it. I'm wondering if I can cost effectively rebuild or replace the transfer case or if I should use the one off of my donor. I also went to a junkyard looking for one but had no luck and I don't know if I should trust a junkyard case. Any thoughts?
Lead Driver
Joined: Dec 2002
Posts: 5,491
Likes: 16
From: Kuna ID
If you have a BW t-case, the oil pumps are known to fail resulting in loss of movement such as you describe. My friend replaced his ZF only to find his t-case was the problem. Rebuild or replace the t-case, my friend got a junkyard t-case for $40 and returned the ZF to get his $700 back.
Logistics Pro
Joined: Sep 2007
Posts: 3,739
Likes: 179
From: Western Mass
They're real simple to rebuild. I had issues with mine engaging the front axle, turns out something just popped out of place, but it gave me a chance to redo all the seals and figure out how it works. Do a search here, or on google. There is a really good thread on rebuilding one someplace, I think I posted a link before.
