transfer case

[cjv80]

So I have searched extensively but can't seem to find the answer to my question, any help would be appreciated.

I'm working on my 2005 Z71, repairing the infamous transfer case pump rub by replacing the housing and installing the plate on the pump assembly. During reassembly and after getting the housing to seat correctly I ran into one hell of a time getting the snap ring to seat. After hours of frustration and prying the the grooves finally aligned and the snap ring seated, making me happier than I can say....until I tried to spin the input or rear tire output shaft by hand. Prior to the snap ring seating I was able to fairly easily spin either shaft, however, after I was unable to spin the shaft what-so-ever....I am able to spin the front wheel output shaft.

My question is....should I be able to spin either shaft by hand once everything is together or is it normal that I can't. Side note I never took the encoder motor off and when I dropped the t-case it was in auto (2 hi). Thanks to anybody that can help, 'm quite desperate and nervous at the thought that I need to take that snap ring off again.

 

[cjv80]

bump...please, anybody that has an idea, i'm trying to get this done tonight. thank you

 

[drakon543]

Best idea i have involves you tearing it back apart. It sounds like something wasnt seated properly and forcing the snap ring in placeis actually pulling on it so hard it binding. Try taking the encoder motor off and manually putting into neutral you might be able to get whatever is bound up jocked into place.if that doesnt Work your going to have to Dismantle it again and find where its bound

 

[cjv80]

Thanks for the input. After a lot of thought I think taking off the shift motor is my next best move. The more I think about it I just don't get what would be jamming up between the housing and the shaft bearing that the snap ring seats into. The ring moves freely in the groove within the bearing and as far as I know nothing else comes in contact with the "long nose" of the housing but that bearing. On to the shift motor I guess....thank you for the idea.

 

[drakon543]

Well that snap ring is intended to hold that shaft in place. If something wasnt meshing just right while you were yanking the shaft back to push the snap ring in place it will bind. Like the old np241 chain drive manual xfer box. The rear snap ring was prone to break and when it did break if you didnt realize what happened it could bind and snap the chain with enough force to bust the case apart.

 

[cjv80]

Well crap maybe I should just pull it apart again, that snap ring was way harder to seat that is should have been. So if I understand correctly you should put the housing on, tighten the bolts then turn it over and place the entire case on something like a roll of duct tape so the weight of the shaft will work with gravity when you spread the snap ring and it "should" fall in place. Any other tips?

 

[SLCHOE]

Have you watched this video?

I don't see the clip causing the shafts to bind up. I'd guess something is not quite right inside but I also always put my T-Cases in Neutral before either inner case work or replacing the encoder motor/sensor.

 

[1998Suburban]

I rebuilt the 246 transfer case on my '98 and was able to spin the output shaft by hand after I reassembled it. That snap ring is a PITA though. I ended up using 2 idential screwdrivers to spread and seat the snap ring. I have a Microsoft Word doc of the rebuild. If I could figure out where to post it you could see what was different on yours.

 

[cjv80]

Thanks everyone, got it figured out. I reopened the case and that moved something into place or realigned something because now the shaft spins freely. I didn't even have to take the snap ring back off. I Re-coated it with Permatex and re tightened everything, so test drive tomorrow. I really appreciate all the input....I was about to set that t-case on fire yesterday.

 

[1998Suburban]

Cool .