Transfer case rebuilding...how difficult?

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H

HemiDave

10 Year 15 Year
Joined
Jan 13, 2008
Threads
15
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66
Location
Austin, TX
Well, the noise I thought was coming from the differential ended up coming from the transfer case. When I dropped the fluid, well, it was ugly. :bang:

Where to get parts from and how difficult to do?

I plan on just disconnecting the front shaft and driving it 2WD.

Thanks!

Dave
 
For all of your geartrain needs your first call should be Marlin. Marlin wants your rebuild to be successful & he wants to see you enjoy your truck.

If this truck is your driver I'd like to encourage you to go to a recycler, or a neighborhood crawler & get a spare case. Then you can enjoy driving with your spare in the truck, & take your time & have fun with that rebuild. Not only can you call Marlin for your parts needs, but his minions will also offer you technical support & answer your questions over the phone. You can also take pictures of anything that doesn't look kosher & post them here. Jerod & Pappy's minions want to help you too...................
 
Thanks Evil,

I don't do much rock crawlin'...mostly wheelin'...ih8mud!:hillbilly: So I really don't need the 4000:1 gear ratios...:zilla: But I did see a rebuild kit that included some lower gear sets...:hhmm:

I might just have to find another case and fix it. My other driver is the dually and not as easy to park and drive in traffic..:bounce2:

Dave
 
The lower gears are very nice regardless of what you do with your truck. The only thing I miss about my stock T-case gears is having a 1.5 high range gear (IE 3rd gear in low range) for going down steep mountains (with the hubs unlocked...)

It took me 10 hours to drop the T-case, and install the Marlin Crawler gears. It was my first time taking a t case apart, and installing the gears is about half of a total rebuild on the transfer case. Not hugely complicated, but you will need a press and some pullers etc.
 
Hmmm...no press. There is one locally for $160. That might be a little high but it would save a lot of time.

Thanks!

Dave
 
2ndGenToyotaFan said:
160 is an ok Price if it's a nice press, but I think Harbor freight has them for less...
Click to expand...

Sorry! The $160 is for a local transfer case! Yeah, I should have worded that better....:bang:

Dave
 
Mike C said:
I would just fill it up with fresh oil and run it for 500-1000 miles, then drain it and fill it again. If its not giving you any problems then run with it.
Click to expand...

Once warmed up, it make s lots of noise...and it causes the truck to feel like it's hitting a pothole since the gear teeth seem to be damaged. It's going nowhere until I disconnect the front drive shaft and repair/replace the transfer case.

The guy that has one for $160 (still in the truck) is coming by this evening. So I might be back in business in 2 weeks.

Thanks!

Dave
 
My first t-case rebuilt took me about 8 hours.

Just remember: There are alot of parts that potentially are damaged, and won't come in a rebuild kit.

If your after stock gearing, I would toss in a good, used case, with a new marlin seal, and call it a day. They rarely go out, so there is a very good chance that $150 used case will work for another 100k miles.
 
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