NV271 transfer case rebuilding suggestions

[Blakers]

I am getting ready to pull the transfer case on my 03 CTD with 6 speed. It has about 318,000 miles and has an occasional loud snapping sound when pulling hard in 4x4. I am sure the chain is badly needing replaced. And the rear output shaft has leaked for years, even after replacing the seal.

I'm looking for suggestions on parts sources and what to be aware of. I've had other transfer cases apart in the past.

Thanks.

 

[Timd32]

My kit from TorqueKing was very nice, it's not a 271 it's the older 241, but the packaging was pretty well done and complete. They had a nice set up for my needs.

Might be worth a look.

https://torqueking.com/category/2003-2018-transfer-case-ram-2500-5500/

 

[Blakers]

Thank you! I see this kit available from Torque King : https://torqueking.com/product/2104...012-nv271d-transfer-case-master-overhaul-kit/ . Looks like everything needed to rebuild it, except the sprockets for $414.98. I wonder why they would include the chain and not the sprockets? I would think they would usually be changed together, but maybe not. I haven't opened mine up yet, but at 318,000 I suspect the sprockets are worn. What about the oil pump? Do those go bad?

I won't order anything until I look at what I have.

 

[MGreer]

Check out rock auto, the rebuild kit they sell is currently out of stock but it looks like they have everything you would need.

 

[cerberusiam]

Chain stretches, the sprockets do not wear much unless the chain is jumping. If you can get by with the rebuid kit then it is all good, if you have wear in the planetary or shafts then it gets a bit more expensive.

 

[Blakers]

Check out rock auto, the rebuild kit they sell is currently out of stock but it looks like they have everything you would need.

Thanks! I searched and it looks like that same SKS kit is out of stock everywhere except a few in Canada. But, when I add the cost of the chain, the kit from Torque King is about the same price.

The chain has been making loud snapping noises when pulling hard, so I expect it has been jumping.

 

[Blakers]

Torque King uses a "Morse" chain, whereas most others are using a "USA Standard Gear" chain. I wonder if there is a difference. The Morse is higher priced and Torque King says it's OEM.

 

[Blakers]

Just found this video. Really good!

 

[Blakers]

This is how she looks inside. Obviously, the chain is stretched. So far I’ve found no carnage. No sludge. Bearings feel good, but at 318,000 miles I think I should replace them.

Biggest problem I’m having is my lock ring pliers are too small and I’m having trouble finding bigger ones locally.

 

[Timd32]

I had the same issue rebuilding my 47RE, took a while to get the right pairs of pliers.

Got some off Amazon.

This is a post from a different forum I screenshot my post.

I have 2 pairs G407P and G409P the one look at the post for the similar looking pair.

Then also got this set.

Amazon product ASIN B01JBIM2CU

 

[Blakers]

I had the same issue rebuilding my 47RE, took a while to get the right pairs of pliers.

Got some off Amazon.
]

Thank you! I'm waiting to see if the Snap-on man has anything on his truck. If not, I'm ordering on Amazon and they should be here by Tuesday.

 

[Blakers]

Everything looks nice and clean inside. Don't see any carnage, so going to order parts now. I could probably get away with just a chain and sprockets, but with this many miles I think I'll replace bearings and seals too. Not sue about oil pump. Been working ok.

 

[Ozymandias]

Please show then a picture with the new chain how much less slack it has. For comparsion.

 

[Blakers]

Please show then a picture with the new chain how much less slack it has. For comparsion.

Ok I will.

 

[Blakers]

I ordered the kit from Torque King, which includes the chain, all the bearings and seals, and miscellaneous snap rings, shims, etc. for $414. And two sprockets for just under $100. I also ordered a new switch as mine has goofed up in the past.
The only thing I didn’t order was a new oil pump. Some have said to replace it and some have said not to. Mine still pumps fine. Torque King wants $105 for a pump, while Midwest Transmission wants $55. Rock Auto has the same part number for about $38. It’s the last piece that goes in, so I can order it next week.

 

[Blakers]

Here's an update. I've got the transfer case all torn down and waiting for parts. Getting the needle bearing for the front output shaft out of the case was a challenge. Since it has an oil gallery hole coming in from the back, the hydraulic grease trick won't work. I ended up buying a Chinese blind hole collet bearing puller Amazon product ASIN B07BNMB42N on Amazon. After some frustration, I was able to get the bearing out. The quality of this tool set has much to be desired.

The other obstacle I am running into is Torque King was short two of the bearings in their kit, so they are holding up my order until they receive them. I wrote to them about it and they have not responded. I could probably get those two bearings locally. My goal was to get everything back together before I have to return to work on the 29th of June, but if I don't have the parts in time?? Once I get the parts, it shouldn't take long to put it together.

 

[Blakers]

Amazon product ASIN B07BNMB42N

 

[Blakers]

UPDATE: Got her all back together and the loud snapping sound is gone! Torque King was good to me. The only issue I had was they held up the kit because of two tiny needle bearings in the shifter shaft that were out of stock. But they got everything to me on time to get her back together before I had to go back to work. Here's an after shot of the chain.

The only other problem I had was Torque King supplied a new oil pump pickup tube that was made out of plastic, instead of a steel tube with rubber hose ends like the original. While installing the oil pump, the end broke off the plastic tube, which made in necessary for me to completely split the case back open and install my old steel pickup tube. I should have used it in the first place.

 

[Timd32]

Good to hear this worked out. Great job on this project.

I need to do mine and get done with my 2nd Gen.

 

[Blakers]

Good to hear this worked out. Great job on this project.

I need to do mine and get done with my 2nd Gen.

It was not a very hard job to rebuild, except for two problems I ran into. First, the lock rings are a bear, so make sure you get some good lock ring pliers that open at least 1.5" (I ordered American-made SKs off Amazon). And the other problem was getting the blind needle bearing for the front output shaft out. Since it has an oil gallery drilled to the back of the hole, you can't use the grease/playdoh/bread hydraulic removal trick. I ordered a Chinese blind bearing pulling slide hammer from Amazon. It got the job done, but the quality is really poor. Everything else was easy!