Well since buying this rig, i found the trasfer case was on its way out, on the test drive i felt the chain jump, PO owner had never heard it do that before. anyways negotiated a lower price because if it and now it finally came time to pull it out for the repair. just finished removing it. now have to decide on getting a rebuilt to save time. or cracking it open and DIY rebuild and start ordering the parts. great way to spend some holidays time right! will update on what happens. the tail shaft case is broken so that back case will be needed already

 

Probably just me but I love to keep everything that came on it, still on it. I would personally rebuild it and put it back where it belongs. I don’t think there’s a lot to go wrong in there and 350 + parts would get it done.

 

Exactly the way I'm leaning on this. also adding rear u-joints and 4by actuator.

 

cracked it open with nothing broken inside i headed over to pick up parts for the repair, and also finally put my wheels on my commuter/parts/material truck "El Beater"

 

Hummer time, T-case assembly, New (used) rear case half, new bearings, chain, bushings, seals.

 

And closed up to dry!

 

What did you use to seal the case?

 

Sealer was Premium Gray Gasket maker by Masters, recommended by the Parts Supplier and they do rebuilds also.

So what i found is the case oiling system failed. sceen clogged and stopped lubricating the main shaft tail section, which burnt the seal first then slow leaked any remaining fluid kept starving the rear till it overheated even more and blew up the rear case and ruined the bearing and soft bushings and one gear wore pretty good also needed replacing. a shifter coupler that has a spring in it for soft engagement was seized from collected debris and therefore made shift engagement really hard for the motor to handle

all in all the 1.6L of fluid in there need to be changed constantly yearly or sooner? depending on yearly milage?? but being AWD everthing in there is always working and bad fluid will start to ruin things quick.

 

Pic of new chain in case rebuilt ready to close up. Then case installed with new slip yolk and new shift motor


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Installed and with new shift motor and new slip yolk

 

Finished up and might as well do one more thing on it that was needed, rear brakes where down to nothing. and theres a shot if the magnaflow.