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Hole in Transfer Case HELP!


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Hello everyone it's my first time posting here!, I drive a 2004 sierra 2500LD Crew cab with the 6L and 4x4.

 

I have been hearing a clunking lately from under my truck towards the front, Upon investigation I found a hole in my Transfer Case! Go figure!. The dreaded pump rub hole.

 

Now of couse I checked alot of other components for where this knocking sound came from, Items like sway bar links/bushing, front end CV axles, Ball joints, front diff mounts, transmission/transfer case mounts, steering shaft and others aswell.

 

Then I looked at the Transfer Case itself (drawing my attention as its covered in fluid/other muck) I had done some research on these dreaded GM Transfer Cases and knew where to look the the rub hole. Sure enough I found one, I had the rear end on jack stands and spun the rear drive shaft by hand. I believe I have found my clunk source! It's a terrible sound coming from within the transfer case itself. I didn't check if it had fluid it was pretty obvious that it's already bone dry or close to it, I have been driving this truck as a dailey driver for quite awhile now and it's probably racked up alot of miles with this condition. With all that said here's my questions.

 

Should I find someone to help me rebuild this thing? (I would need to replace alot of components inside I imagine)

 

Or find one in the scrapyard and do the aftermarket pump replacement which cures this problem (I would be taking a gamble if the components inside are any good)

 

I'm not willing to buy one already rebuilt from a company as their prices are steep and just to ship my old one to them for core would be outrageously expensive.

 

I'm not afraid to tear into this myself but I would much prefer someone with knowledge/experience on these items, I do have most tools required except good snap ring pliers and tools needed for the bearings.

 

If anyone has any good suggestions as to cheap options that would be great! I would love to find someone local that has done these and pay them to help me rebuild it!

 

If I left any information out let me know and I'll promptly post a response

 

Also I do have photos of this Transfer Case and it's tag but my images are too large to upload

 

It is a GM 246

 

Happy trucking!

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As long as someone that is experienced with rebuilding these units, then I'd go that route. I'd replace everything to include the back half of the case itself. When I bought my truck the transfer case was leaking and the remaining fluid in the case (which was only a few ounces) was black and smelled burned. I found a salvage yard that yanked and reserviced a full case for me. They were nice enough to exchange the input/output shafts for me.

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  • 5 weeks later...

I found mine low on fluid and in the black burnt condition. Had to replace both shift forks, mode synchro, and all bearings and seals. They are still pretty pricey to rebuild I replaced no shafts or any part of the case and have over $500 into parts. I patched the pump rub areas inside and out with a couple coats of JB weld. Then I installed the sonnax pump plate kit. No issues so far.

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Sorry for the late response, I have ordered the pump rub fix from merchant auto (the pump housing) not the little metal shim thing. I have not installed it yet but have patched the hole in the meantime (I used JB weld and a piece of cut and shaped aluminum I had lying around) It's a good solid patch and has held in the new fluid inside for a good time now. I'm well aware this is not a permanent solution but is a bandaid for now. The internal components appear to still work properly but I will need to rebuild the encoder motor with a new sensor/encoder ring? And gasket for it.

 

My next question is, What are the clutches inside the transfercase used for? Are they just for the auto 4wd? if so can I just get away with putting it in 4wd manually. Or are the clutches absolutely needed for the front output regardless of auto 4wd or manual 4wd? Also thanks for all the replies!

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  • 2 weeks later...

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