After suffering another series of events where the transfer case pops out of gear while descending hill and threatening lawsuits in the event of my death I finally got DC to do something.
The tech folks had the dealer order a series of parts and had them partially tear the transfer case apart. They were asked to measure the length of a shaft, the indexing of the holes which align the transmission and transfer case as well as inspecting the mating surface between the T/C and the transmission.
Well, they found that the mating surface on the transfer case had machining that appeared to be produced by a CNC machine gone insane. With that problem repaired so far I haven't had a repeat problem. Good news!!
The techs at DC have obviously seen this problem before because of the detailed instructions given to the dealer.
The tech folks had the dealer order a series of parts and had them partially tear the transfer case apart. They were asked to measure the length of a shaft, the indexing of the holes which align the transmission and transfer case as well as inspecting the mating surface between the T/C and the transmission.
Well, they found that the mating surface on the transfer case had machining that appeared to be produced by a CNC machine gone insane. With that problem repaired so far I haven't had a repeat problem. Good news!!
The techs at DC have obviously seen this problem before because of the detailed instructions given to the dealer.