Transfer case issues

Hoke Durham · June 17, 2019

Hey new here but am hoping to get some insight on a problem I'm having. I recently had my transmission rebuilt at my local transmission shop. The problem being once we had everything put back in the truck (Transmission, drive shafts transfer case and all) I had no power to my front or rear driveshafts. when I say no power I mean no rotation what so ever. So we pulled the transfer case back out and started the truck and dropped it in drive and reverse. The tail shaft moved freely in both directions. we tried manually shifting the transfer case into all positions still no rotation on either output shaft. Any ideas?

davester · June 18, 2019

Is the TC still out? If so, does spinning the input shaft by hand turn either output shaft? Shift it into 4lo and check again? How does it feel to spin the input shaft by hand (does it grind, or feel like you aren't spinning much)? Try spinning the input shaft while changing from neutral to 2wd to 4wd and see if you feel anything different while shifting?

When you installed the TC, did the TC input shaft actually engage with the transmission output shaft? It took some wiggling to do it, when I installed my TC. If not, then possibly the transmission shop installed the wrong output shaft or the wrong TC adapter plate.

Hoke Durham · June 18, 2019

Yes I can turn the input by hand and I get rotation to both outputs. that's what has me stumped. Why does it work When its on the ground but doesn't work when behind the tranny? We also tried to turn the outputs with the transmission in neutral when it was installed and we could not get them to move so I must have spline engagement or at least in my mind I do because it turns so freely outside the truck. with the TC out of the truck and the transmission in neutral you can turn the transmissions tail shaft by hand. I'm wondering if there's a bearing problem or something that only shows up when you get everything hooked up? Maybe a shaft in the TC is getting cocked a little and locking the TC down? I don't know at this point

davester · June 18, 2019

Sounds like the TC isn't properly engaging with the transmission for whatever reason.

When you install it, you should have to lift the TC up to the rear of the transmission, then get the TC input shaft on the transmission output shaft, then shift the TC towards the transmission about 1-2", then bolt the TC to the adapter place.

You might measuring the diameter of the transmission output shaft, and compare the diameter to the I.D. of the TC input shaft, as well as check that the trans output shaft sticks out far enough to go well into the TC input shaft.