Transfer Case Problems

[Todd G]

I have a problem with my transfer case again. For the second time in 25,000 miles, I have broken the snap ring on the output shaft of the transfer case. My truck has only 58,000 miles now. The bill from my dealer states the ring costs $3. 80 and the labor $175. 00. When the ring breaks, you can't apply any power or you get a grinding noise from the case. The dealer says he has never had another snap-ring failure in 7 years other than my truck. My truck has way more power than stock, but I've never heard from anyone else on the TDR with the same problem.



You guys have any suggestions?

 

[Sled Puller]

Yup.

Contact Dave at www.enterpriseengine.com

He has broken everything that will break, and has come up with fixes- for most of them.



Gene

 

[Strick-9]

The snap ring is broken in my T-case right now. It didn't break in two and fall off yet. But a piece of it did break off.



I'm having trouble finding the right one to replace it.



I don't know how long it's been broken. Just found it last month.



You're not alone.





-Chris

 

[Sled Puller]

Do you guys have the HD? Or the standard?

Now I'm nervous.

 

[csutton7]

the snap rings are of poor quality and can be upgraded--I'll have to do a search(other computer had all the info & it decided to have a melt down) and find the place in Oakland,CA that uses better parts when they do their rebuilds---chris

 

[csutton7]

found 'em--give these guys a call--they're very good--- www.transfercases.com ..... chris

 

[JJW_ND]

Pre98 versus 98 and up TCases

Any difference in the pre98 versus the 98 on up Tcase?



Is it just the linkage?



I replaced my 5sp in my 96 with a 2000 5sp. Different shift lever that does not fit the old boot very good.



If only the linkage in the Tcase is different, maybe I could switch to the newer linkage and add the 98 and newer floor boot to better seal up the shift lever.



Anyone try to use the newer foor boot with a 97 and older shifter (tcase) setup?



jjw

ND

 

[Don M]

I broke the snap ring in my 95 two times with a stock v-10 engine. It was the HD transfer case (I ordered it that way)

The snap ring breaks and the gears inside rub together causing the grind. I have not had a single failure with my 97 model transfer case in my 3500. Its a HD transfer case too. It has 200,000 miles on it.

On the last breakage we made our own snap ring and used a large piece of pipe to hammer it on the shaft. That was about 100,000 miles ago with daily hard driving. Maybe it is fixed now.



The first time all the grinding occured the gears were ground up pretty bad. I have not heard of the newer cases after 96 having the problem.



Don~



there is another member here by the name of Mtn Goat. He has broken three or maybe four snap rings in his. Its a 96 model.

 

[Joseph Donnelly]

To get a better fit of the 98-up shifter in the 97-back boot, go to Home Depot and buy a length of Armstrong brown pipe insulation, sized for 3/8" iron and 1/2" copper pipe. Put a piece over the shifter and use black electrical tape around it. Now the hole in the boot will be just right.



The other way is to use the 97-back tower assembly and shifter on the 98 trans.

 

[pwknapp]

How do I know if I have the HD transfer case or not?

 

[Blakers]

Where exactly is this snap ring located? Never heard this problem mentioned here before.



Blake

 

[Sled Puller]

I believe the HD's have the 6 bolt PTO cover, the small ones do not.



Also, the tag underneath your hood should read '241HD"

 

[FParisi]

This happened on my non- HD case. My understanding is that when the snap ring breaks it allows the 4 WD gears to slide back and forth. Mine messed up gears in the transfer case before I figured out what was going on - $$$!

I've seen mention of this in other threads- a while ago I think. If you hear a noise like its trying to go into 4WD get it fixed right away! Maybe putting it into 4WD til you get home would save the gears.

Frank

 

[Strick-9]

This seems to be a common problem. Read this website for more info.



http://www.sonnax.com/bulletins/tech/T3-EL-399.pdf



I'd be willing to bet that mine broke due to hard four wheel drive launches. With all that torque on the splines of the driveshaft you experience spline lock. The driveshaft was designed to move in and out of the transfer case to prevent bind up as the rear suspension compresses. But when the splines are loaded with a few thousand ft-lbs. in a hard launch and the rear suspension compresses due to 0. 7 g's of acceleration the splines cannot slide on one another easily and all that force is exerted on this snap ring.



-Chris

 

[Jeff Knight]

Todd, Ihad this twice in my 95 truck. The second time it hapened I needed to use my truck for a while before it was fixed. I took the front driveshaft off and ran it in 4x4. The dealer told me that doing that saved the case from distruction. It holds the gears in place. Hope this helps. It was the standard case. Jeff

 

[Pit Bull]

Originally posted by pwknapp

How do I know if I have the HD transfer case or not?

It's printed on the metal label on your transfer case.