2004 Z71 Tahoe NP 246 Transfer Case Swap Question

[Rusty]

Hey guys, I had a pump rub and failure (complete annihilation) of the transfer case.

I picked up an np246 from a guy, pulled the old one, went to swap the motors and the new one has a square cam and my old one has a star style cam.

Is there anything I can do or swap to make my old one fit this new transfer case? The new one has an extra plug outlet built on it and a cord.

My old one just has a cord. Any info helpful! Thanks so much!

-Rusty

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[Rusty]

What im wondering is if i can open the encoder motors and just swap the gears with the matching cam on the case.

 

[retiredsparky]

I can't comment on your dilemma, but if you do keep this replacement case, I hope you modify it to fix the pump rub problem. The clip that GM uses to act as a thrust washer in both 1/2 and 3/4 ton vehicles eventually will fail. The oil pump constantly spins when driving in both 2WD and 4WD. The new real thrust washer is less than $30 including freight and will last forever. Several companies make them.

 

[Rusty]

So after a long process or trial and error, this is the solution I came up with.

I removed the shaft plate that sticks through the case and put it into the new transfer case. I put everything back together and there was rubbing on the shift fork. I removed the shift fork from the new case and put the old ground up one in and everything functions fine. Ill be sealing the case tonight, and installing in a couple of days after the seal cures. THE OLD CASE WAS DESTROYED. I posted some pics of the old case so you could see the failure and all the shavings that were left behind caking the entire inside of the old case. Thought you would get a kick. No pump rub hole. I'm assuming that the bearing that's all jacked up is what failed and caused all the mayhem. Maybe you will see something I don't. Thanks guys for reading. Ill let you know how good it works after i get it installed. BTW.... It still drove before i took it out.

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