[R.Cassidy]

Today i went to see why my 4wd isnt working. Figured i would start with fluid. Opened the plug and 2 drips came out Went to fill it up and got 3/4 of a quart in and it started coming out through some grease on the side. Got 2 little holes in it. How can i fix them? Apoxy? Help please.

 

[Len Todd]

I suspect you will need a rebuild. If there was no fluid in it, you trashed the internals. Also, with the holes in the case, you are going to al least need a new tail-shaft. But until you open it up, you can't really tell if the rest of the case is any good. Probably time to start looking around for a new or used TC.

 

[JustAnotherCummins]

That's actually a pretty common problem, there is al oil pump splash guard or something of the sorts that moves around and creates the hole, chances are epoxy won't seal it up completely, but it may help.

We've replace multiple t-fer cases because of this.

 

[Hondarider552]

remove tcase, buy TTS pump rub fix kit, and JB weld the holes back in. Did this on an 01 last weekend and held up good so far.

 

[R.Cassidy]

Whats the tts pump rub fix kit? So something knocked the holes in it from the inside? Is that where the fix kit goes? sorry

 

[JustAnotherCummins]

here is just one version of it

pump_rub_fix_transfer-case-pump-upgrade-kit

 

[R.Cassidy]

Yeah i just looked it up. I guess ill take my transfercase apart and see if its shot. Then if its not ill put that in. I leave may 3rd for the army so idk if ill have time.

 

[R.Cassidy]

Are transfercases the same on gassers as diesels? that would make finding one way easier.

 

[amo]

good luck man just purchased a new one for mine because there were no used ones to find and the parts were close enough with the dealer warranty to get it there....3 years 100k miles parts and labor! i had 950 dollars worth of trashed parts and then another 250 for a new yoke and u-joint....so figured might just cut time short and get new one...i would still recommend tearing it apart and adding up the parts...maybe you will get lucky...before you start look up instructions on how to replace pump first....the rear bearing that has an external clip is a little tricky to get out....take out speed sensor and the rubber plug...my external clip was busted so i used vise grips and ripped it out...either way makes it tons easier to get out....and it is the correct way...pm me if you need help drivetrain.com was a god place... a local trans place had all my parts in stock....except the yoke...good luck!

 

[farmerkirkie]

Rebuild what you have. You could weld up the hole or epoxy it. You use the pump rub from Merchant or Transfer Case pump rub kit - Adrenaline Truck Performance this from ATP. I think Merchant sell the new tailpiece to.

 

[R.Cassidy]

Alright guys thanks for the help! Im gonna take it out today or tomorrow and see what is going on. Ill probably have to take the transfercase in somewhere cuz i got no idea how to tell what needs replaced and what doesnt. getting it out for me is hard enough lol but i will for sure get the kit if i dont get a whole new case.

 

[BGD-09DM]

Is this a problem with all years? Should I be installing this kit in my 09? Thanks

 

[R.Cassidy]

Im thinkin its just 01/02. They probably fixed it so it dont happen on the newer models. But im not sure.

 

[Stiemy]

Im thinkin its just 01/02. They probably fixed it so it dont happen on the newer models. But im not sure.

I just last week had my case welded and put in the Merchant Automotive upgrade kit and new seals. I have an 04' so it is not limited to just the 01/02 models. It is an easy fix if you are at all mechanically inclined so don't be scared to take it apart not much to it. Give Nick a call at Merchant he will take of you and the shipping was very fast, ordered my stuff on a Thursday afternoon and had it Monday.

 

[pezsez]

id weld it up for you but im here in southern cal :ar15:gungun1
if it wer eme id make sure you internals arnt fried.

 

[gixxersixr]

What are you guys who are welding the case holes using for fill rod. I was told the cases are magnesium and I asked my buddy who welds if he could fill the hole in my t-case but he said that magnsium fill rod is stupid expensive.

Thanks....

 

[R.Cassidy]

I can weld up the holes. I just gotta make sure nothing is messed up on the inside. does the kit replace what went wrong in the first place? or does it just prevent it? will it fix the spring that fails?

 

[knaffie]

It won't fix anything if yours is trashed now. It prevents the vibration that makes the hole.

 

[R.Cassidy]

So if stuff is messed up inside, replace all the parts (or get a new one lol) and put the kit on?

 

[R.Cassidy]

and what is the difference between the two kits in the links on this thread? on is $50 the other is $150