Transfer case assembly fricka frack!

[OR VietVet]

After I got in there with a couple cans of brake clean and cleaned the entire rear half of transfer case, I can see what I thought was a pin hole and is not. I am going to look at it again in about a week. I am convinced that the output seal is not leaking.

 

[Fless]

Here's a bit more of a hint of where to look for the pump rub pinhole, courtesy @rockola1971:

Transfer case whine

I have a 2002 Tahoe and the transfer case whines while in 2high, it gets quieter while under a load and goes away when shifted into 4high. Seems like the chain could be stretching and whining while not under a load. I am capable of rebuilding the transfer case myself, but there are so many...

www.tahoeyukonforum.com

 

[strutaeng]

After I got in there with a couple cans of brake clean and cleaned the entire rear half of transfer case, I can see what I thought was a pin hole and is not. I am going to look at it again in about a week. I am convinced that the output seal is not leaking.

Maybe add some UV dye and check again?

 

[rockola1971]

Check red dot marked area all the way around rear case half. Yellow circle marks an actual pump rubhole. Check that area all the way around the case. For some reason the rubholes almost always end up on the passenger side of the case rear and usually on the top half.

 

[InterceptorF]

You can replace the T-case without removing the torsion cross-member. It is easier with two people (and your tongue sticking out to the left .

 

[OR VietVet]

Just last week, I crawled under and everything was dry. No leakage so far and plan to check every week. Level ground and the "blue" fluid was right at the bottom of the fill hole. No noises recently. Crossing fingers. My other noise over bumps and undulations was a loose nut on the attaching bolt for the right rear sway bar link. Tightened both sides down and no noise. The T-case swap is on hold for now.

 

[V327839]

I have removed and installed the transfer case on an 03 Burb without removing the crossmember. It’s not so bad. Just gotta turn it sideways and it drops right out.

I second this. I don’t look forward to it either, but I did it by myself on my back in the driveway. Remove the tcase mount and let it rest on the crossmember to get enough clearance for the top bolt. And get a super shorty wrench.

 

[OR VietVet]

Here we are 3 months later and still is dry. I have no idea what I thought I saw before. All fluid levels good and look fine.