Transfer Case Output Bearing Replacement 04 2500hd

[tater85]

Getting a grinding noise at low speeds in 4wd, oil levels are good. Rear output seal leaks, rear output shaft has 1/16 to 1/8" of play up and down, same as for front output shaft. When parked and in 2wd and turning front drive shaft by hand the grinding is in the front output shaft bearing area. I am assuming its toast.

 

What tools are necessary to replace bearings, can I do this job without removing transfer case (it looks like I can)? Do I need a seal and bearing puller? It looks simple to me I have worked on axles but never a tcase. Just looking for some tips and what is needed before I tear into it.

[Spurshot]

I just had my transfer case rebuilt. I watched my friend's shop mechanics drop it out in about 30 minutes. The mechanic was the greenhorn of the shop. You'll want to take it out. You may want to consider just buying a rebuilt one from someone like Transfer Case Express or others. If you rebuild it yourself, you'll need to have the tools and experience or knowledge/information on what to look for when it's disassembled. They typically eat a hole on nearly so in the area where the tabs from the oil pump rub after a little steel wear preventer clip breaks. If this happens, the case needs to be TIG welded. There's a retrofit kit that improves this area to prevent the rubbing and damage. The chain should also be replaced ($100) during an overhaul. If your transfer case is an "Auto-Trac" type where there is a round button on the left side of the dash that says "Auto 4 wd" or similar, it will have a clutch pack like an automatic transmission that also should be replaced. The rear bushing that centers the yoke for the rear driveshaft needs to be replaced at overhaul as well. That's where the rear driveshaft on yours is getting it's slop.

 

Frankly, If you don't have the tools and a good overhaul manual for the transfer case, I think you should just buy an overhauled unit.