|04-25-2012, 10:01 AM||eBay Motors #1 (permalink)|
Join Date: May 2010
Transfer Case replacement
I just found out that my transfer case has a whole in the bottom and It is binding up. Feels like something is getting caught between gears and bottom line is needs replace.
My question is how difficult is it to replace. I am mechanically savvy but have never pulled one of these apart. I would be doing this on the ground on my back. Shop wants 2400 to do the repair. Thoughts? suggestions?
2002 2500HD 4X4 with the 6.6L and Allison transmission.
No add ons.
|04-25-2012, 12:08 PM||eBay Motors #2 (permalink)|
Join Date: Jul 2010
I did my tcase fix myself, I'm a welder so that helps. it's a magnesium case so welding know how is critical, your cheapest bet would be to remove the tcase, just use a floor jack. open it up, remove housing where hole is, give it to a good welder, be sure to tell him it's magnesium. then inspect the tcase for worn/damaged parts and replace as necessary. when I first detected the hole I removed right away and repaired the hole, cost me about 100bucks in parts, gm has a updated clip for the pump, I wouldn't bother with the aftermarket, pump plate assy's (kennedy diesel, etc.) They are not necessary IMO, the gear guy I deal with says after the tcases get the updated 8 dollar clip, he never see's them again. I will refer you to my gear suplier : Border Parts, 3875 Bancroft Drive Spring Valley, CA 91977 (619) 461-0171 the guy is a whizz. At very least I would remove and open to assess the damage. Good luck.
04 silverado 2500 hd crewcab 4x4 lb7 FASS platnum lift pump, Nicktane adapter running cat filter, air horn port mod, everything else stock.
|04-25-2012, 01:21 PM||eBay Motors #3 (permalink)|
Its not hard to remove the tcase. Its as straight forward as it looks.
Sent from my old skool Droid
Lots of miles
Built by Husker Diesel
1995 Chevy 2500 - 12v/NV4500 Swap
|05-28-2012, 08:11 AM||eBay Motors #4 (permalink)|
Join Date: Oct 2008
Location: North Dakota
07 CCSB LBZ, ProFab EGR delete, ISSPRO pyro&boost, Edge Insight CTS, Blue LED steering wheel controls
97 Honda Prelude
08 Yamaha Apex MTX 40th
11 Yamaha Nytro XTX
13 Yamaha Superjet
|05-28-2012, 08:50 AM||eBay Motors #5 (permalink)|
Duramax Lifetime Supporter
Join Date: Jun 2009
Location: West Monroe, La.
It's not that bad of a job, but you will need a clip ring tool to remove the rear case half and all the bearings. I'm sure someone has posted a DIY on here somewhere. If it's come to the point where it is binding you'll have to order new syncro's, mood fork because it will be chewed up. Ask me how I know this. You can get all the bearings from your local bearing dealer or you can order a complete kit seals and all for around 150 on the net. The syncro's will run you about 120 for all three components. Go ahead and order a new aluminum tail housing it will come with a new yoke bushing installed and the pump kit from Merchant Auto is worth the money. I've had to do this to both of my trucks.
2005 LLY CC SB 4X4 Ranch Hand Bumpers, 265/75/16 BFG'S A/T'S, EGR Blocked and FingerSticked, MB Gunner 8 Wheels, Banks 4" Monster Exhaust with MBRP Cat Delete Front Pipe, AFE Bladerunner MP, PCV Reroute, All Lights ON Mood, Nicktane CAT fuel filter, AirDog 100, Amsoil Fluids and more go fast goodies soon!.
|05-28-2012, 09:21 AM||eBay Motors #6 (permalink)|
Join Date: Apr 2010
Location: Schuyler, NY
If you get the case apart and the planetary is toast you may just as well get a new or reman case. Reman cases used to be cheap( relatively) through GM and came with the best warranty.
01 GMC 2500hd ecsb Dmax/Alli. 4" exhaust to 5" single stack,EDGE Insight CTS, EFI Live Moonshine tuned, Suncoast stage IV, Complete Kryptonite front end with PISK , 305/55/R20 Cooper Zeon's on Rockstars. Eaton E-locker. So cal stage I heads, and a little bit of laughing gas.
07 LMM LTZ CCSB. S475 over stock compounds, 40% over dipper sticks, Suncoast tranny by Freedom Diesel, Air Dog, ATP tuned.
|05-28-2012, 09:33 AM||eBay Motors #7 (permalink)|
Join Date: Jun 2011
Location: Bellingham, Wa
It is very easy though. Pull both driveshafts out, disconnect all plugs/wiring, put a jack under the tranny and pull the crossmember out that supports the trans. Then you have like 6 or 8 nuts holding it to the trans(dont remember exact #). Take those out, slide it backwards a little then point the front of it towards the ground clearing the trans and pull it out forward(going towards the trans). It should only take like 30mins to take out given you have air tools or friends to help. I dont recall all the socket sizes for the bolts. Youll need wrenchs for the tcase nuts
01 LB7 EC/SB Ally 4x4
DD: 1990 4runner completely stock 4x4 3.slow
2007 Yukon Denali - Hers
Big Thanks To Adrenaline Truck Performance, Alligator Diesel PerformanceSocal Diesel and Lincoln Diesel Specialties
Last edited by Thebiggids; 05-28-2012 at 09:37 AM.
|05-30-2012, 12:03 PM||eBay Motors #8 (permalink)|
Join Date: Nov 2010
Location: Zeeland, MI
We stock tansfer case parts, the upgrade kits, and fully reman units.
Transfer Case LB7 Duramax 261XHD 263XHD
Once you follow the above link
click on either the 261XHD(manual floor shift) or 263XHD(push button) picture
|12-08-2014, 01:28 PM||eBay Motors #9 (permalink)|
Join Date: Dec 2012
Location: The great nation of Texas
I see this tread is pretty old but I thought I would throw it out there anyway. I am about to pull mine this weekend and rebuild it (hopefully) but I have never rebuilt a transfer case before.
A. Any words of wisdom IE do's and don'ts
B. A location I can find a video on rebuilding a 261 XHD
C. Any volunteers to come drink beer and laugh at me. (Wylie TX)
I ordered the master rebuild w/chain and rear casing from Sleeeebay
|12-08-2014, 03:46 PM||eBay Motors #10 (permalink)|
Duramax Lifetime Supporter
Join Date: Aug 2014
You'll need a pair of lock ring pliers that open up at least 1 1/4".
The cheap pairs only open up 15/16".
2001 LS CCSB 4WD
Lift pump / water separator / nicktane CAT
Danville modified turbo horn / Pypes downpipe / PPE boost valve /
Pump rub fix