BW4485 Transfer Case Rebuild DIY?

Campbesl · Oct 10, 2024

Hey Folks!

At 200,000 miles my 2012 Yukon Denali XL has a lot of clunk going on in the transfer case. It is easily traced to the transfer case by individually grabbing and twisting the front and rear drive shafts; the lash in the chain is very obvious.

I see rebuilt units on EBay for $995 plus taxes and shipping. Locally I've gotten quotes around $1200 but that is ****.

I found a thread on here where someone linked a parts list for a total of about $300. What I need is a good set of DIY instructions so that I can do it myself.

I hope that everybody is safe after hurricanes Helene and Milton.

Best regards,

Scott

Geotrash · Oct 10, 2024

Campbesl said:
Hey Folks!

At 200,000 miles my 2012 Yukon Denali XL has a lot of clunk going on in the transfer case. It is easily traced to the transfer case by individually grabbing and twisting the front and rear drive shafts; the lash in the chain is very obvious.

I see rebuilt units on EBay for $995 plus taxes and shipping. Locally I've gotten quotes around $1200 but that is ****.

I found a thread on here where someone linked a parts list for a total of about $300. What I need is a good set of DIY instructions so that I can do it myself.

I hope that everybody is safe after hurricanes Helene and Milton.

Best regards,

Scott

It's not a difficult job. The hard part is the planetary set needs to be clocked right for it to work when you're done. There are some YT videos out there of guys rebuilding very similar TC's that might be helpful.

The BW4485 in my '07 has had a ton of slop in the chain for the past 55K at least. It makes for some clunks, but so far it's holding together. I could rebuild it on the bench but I found a local shop that will do it, including R&R labor for about the same as a reman would cost for just the TC.

donjetman · Oct 11, 2024

Campbesl said:
Hey Folks!

At 200,000 miles my 2012 Yukon Denali XL has a lot of clunk going on in the transfer case. It is easily traced to the transfer case by individually grabbing and twisting the front and rear drive shafts; the lash in the chain is very obvious.

I see rebuilt units on EBay for $995 plus taxes and shipping. Locally I've gotten quotes around $1200 but that is ****.

I found a thread on here where someone linked a parts list for a total of about $300. What I need is a good set of DIY instructions so that I can do it myself.

I hope that everybody is safe after hurricanes Helene and Milton.

Best regards,

Scott

youtube is your friend

petethepug · Oct 11, 2024

Another owner of an 07 AWD Esky rebuilt his with a kit of said parts. He wasn’t liking the results based on his other identical extremely low milage truck. He swap the xfer case from one to the other. Day & Night difference with the one of same age but 30k miles vs rebuilt with 180k.

The AWD case are easy to rebuild but as stated, tolerances are critical and must be accounted for. Stop by a diesel Indi shop that specializes in Frequently rebuilding them. Have your orig unit rebuilt vs mail ordering from unknown origins. Expect 6-$9h and to have the truck gone for a day or two.

Transfer Case Swap Help

I have a 2012 Yukon Denali XL 1500 6.2l AWD with 195K miles. The transfer case (TC) has developed a lot of lash evident by lots of clunking. It's bad! Time for a reman TC. I've watched all the relevant videos and searched thoroughly for DIY directions but haven't found anything really good. 1...

www.tahoeyukonforum.com

BW4485 Transfer Case Rebuild DIY?

Campbesl

TYF Newbie

Geotrash

Dave

donjetman

Full Access Member

petethepug

Michael

Transfer Case Swap Help

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