Engine/Transmission (1998.5 - 2002) Once again my tranfer case is failing!

[JNeiman]

My transfer case has already failed about 4 months ago while towing a boat, and now its going again! I have a remanufactured one now, with a 12,000 mile warrenty, which fortunately is not near running out. But what the He!! is goin on here? I do not abuse the truck, tow heavy, or use 4WD often. I took my mechanic friend for a ride because it was making nasty noises occasionally throughout the day, and he got under and said it was much hotter than it should be, or atleast the pump part (between the transmission and transfer case). What does this seem like? I am really getting upset. It is slamming and grinding like its skipping teeth or the chain is skipping. I need some advice! Thanks guys, JOE

 

[rhirsch]

Did you ever find out what the problem was? Mine jsut started doing what sounds like the same thing from your description. I have a 95 1 ton 4x4 and I'm afraid it is on the edge of something very bad. If anyone knows please help.

 

[NETim]

snap ring

This has never happened to me, but I've read that the snap ring on the rear output shaft can break and allow the shaft to drift forward. This allows gears to grind together inside the case and naturally put the kibosh on the works.



There are others here naturally that know much more about the situation, but I thought I'd drop my $. 02 anyways.



This place has a fix if you're experiencing this problem.



Seems to me that standard cab trucks were more prone to this problem due the shaft angles involved, but maybe it was SB trucks. I can' remember.



Good luck,



Tim

 

[JNeiman]

My mechanic who was at a near total loss of what it could be for a few days, but thinks he might have found the problem. From what he told me its an aluminum "fork" in the linkage that blew appart for no apparent reason. Anyways, he got the part yesterday and he is gonna keep the truck all weekend and drive it, so hopefully we have found the issue. Thanks for the input!

 

[rhirsch]

transfer case

I have just removed my transfer case and disassembled it. I found that both the mode shift fork and the range shift fork were badly worn. Apparently the plastic liners on the forks failed and allowed the forks to make contact with the spools; the forks lost. This was allowing the transfer case to try to shift itself into low range while driving under power, not a good thing. It was very much like gears hitting. surprisingly the gears themselves are in good condition. Another thing that I found was that the forward input bearing was displaced, it had shoifted forward about 1/16" allowing the planetary gears to start to contact the case. The total for the new parts will be approximately $350. It includes the two forks a real output seal, and a new rear transfer case half (which had a crack in it, I chose to replace it for $150 rather than weld it, but I might just weld it and keep it for a spare, I haven't decided). Hope this information helps.



'95 1ton 4x4 5spd club cab slt laramie cummins dsl.

 

[Chris N5CWM]

rhirsch, how many miles on your truck?

 

[rhirsch]

I have 145,000 miles; not nearly as much as I think I should have for something like this. I am an aircraft mechanic by trade, and have maintained the truck beyond what the heavy maintenance schedule calls for. I have always believed, and still do, that good routine maintenance is the best. But even though I changed the transfer case oil every 24,000 miles I still had this problem. I have also added checks and inspections to the program when ever I learned that something else needed attention. I will probably add an inspection to remove the cover plate on the side (for pto mounting) at oil change intervals to inspect the plastic fork liners for wear/damage now.

 

[Chris N5CWM]

I agree, 145,000 isn't a big factor.



Which transfer case is it? Mine has the New Process 241 HD.

I have about 46,000 on mine and have never changed the lube.

I'll have to do some research on the best lube for the transfer case and get it done along with changing the front axle lube.

I have the new Mag Hytec Dana 60 front cover and several quarts of Amsoil Series 2000 sitting in the garage just waiting for me to get around-to-it.



I seem to recall that the transfer case uses regular Dextron or Dextron II.

 

[Texas Diesel]

My transfer case calls for the newer Dextron III+ or 4. I put Royal Purple Synchromax in and it works fine. The Synchromax is rated by RP to replace ATF.



rhirsch, there is a company that makes a set-screw collar to eliminate the snap ring completely, you arent the only one to have this problem. I cant remember who makes the collar but hopefully someone will have the url.

 

[rhirsch]

I have the 241HD, I don't think you can get the 241 (regular duty) with a 1 ton. As for the bearing being displaced forward, it appears that the seal housing is designed to retain the bearing, but in my case, I suspect that they used a little too much RTV under the seal housing which allowed the bearing to move. My manuals specify Dexron II or better, I have been using Dexron III which is supposed to replaced (and exceed) Dexron II. As for the collar with a set screw; I have more faith in a snap ring than a set screw, screws loosen at various frequencies, snap rings do not (aviation 101).

 

[CumminsPower98]

The Collar bolts get loctite to hold them in place, I don't think there would be any problem at all. I would sure trust one if I installed it on my truck. I wonder if it's worth doing this for preventive on a '98. Anyone heard of broken snap rings on '98's?

 

[Steve Campbell]

NETim replied... a few posts above.





"This place has a fix if you're experiencing this problem. " Texas Diesel, You may want to highlight that site, it is a good one.