ok well it happened to me finally, have the pump rub hole. The stealership estimated it around 1200... they said that it includes an updated version of the new housing so i guess that it'll never happen again. Has anyone done this fix themselfes and if so how hard is it for a person with a little above average mechanical ability to preform?

you can do it, there is a DIY here I think.

This place is awesome i love the response time.

I just bought the piece that is supposed to prevent that from happening, so i'll be diving into it shortly.

Check with Merchant automotive, they sell the tail cover for substantially less than what you were quoted.

At least you caught it early and didn't trash the whole case

yeah im glad too i noticedit when there was fluid dripping from the rear diff it was actually blow by from the tranny:(. This is what i got from merchant automotive


263XHD Seal and Bearing Kit $170.00
B27 263XHD/261XHD Rear Housing $300.00
Transfer Case Pump Upgrade Kit $250.00

Subtotal: $720.00
Shipping & Handling: $19.70
Tax: $0.00
Order Total: $739.70

not too bad for whats almost a new transfer case :)

Anyone in or close by camarillo california (93012) that might be albe to halp me with my transfer case when i get the parts in?

plenty of info the in drivetrain section; do a search for "pump rub" and you'll have enough to read until the weekend!

Go to Merchant Automotive site and there is a detailed procedure with pics for taking apart T-case and installing their "fix" kit. Even if you use a different kit, the instructions with pics on M/A site will help you out a bit and are very clear and detailed.

It is very easy to get your t-case apart if you have the right snap ring pliers.

Moved to Drivetrain...

I just did mine last week, same deal it cost me $1,200.00 for the rebuilt transfer case. Here's the kicker; after waiting 5 days for the case when it came in it had epoxy on it where a hole was fixed. I called both GM and the shop that did the repair and I was told that it's a GM certified repaired and it's covered for two years. It does have the updated pump housing so it won't wear through again. I did the removal and replacement myself and it took about an hour and a half to remove. Not hard to do at all, just make sure you get the wiring disconnected before you start moving things around, the sensors are easy to break.
Since the truck was down for five days I also removed the trans to take care of a small leak in the bell housing too. It's been a week now and all looks good, no leaks, not even the epoxy fix.

This repair is very simple even for a novice part time wrench turner. I just repaired my case installed riverside gear pump rub plate and even changed some modesyncros adn the mode range fork and a couple of bearings all for under 200 bucks!!! It is as good as new and will never rub thru again. Well worth your time to repair yourself!!! Jeff

thats awesome to hear i got the MA pump rub kit (thanks dad) i was a bit worried about how i would get it done when it arrives next tuesday

It is very easy to get your t-case apart if you have the right snap ring pliers.

X2

Getting the external snap ring off and back on is tough without a good SR Pliers.

hey can i just take off the back cover with it on the truck or do i have to remove the whole transfer case from the rig?

I just did mine last week, same deal it cost me $1,200.00 for the rebuilt transfer case. Here's the kicker; after waiting 5 days for the case when it came in it had epoxy on it where a hole was fixed. I called both GM and the shop that did the repair and I was told that it's a GM certified repaired and it's covered for two years. It does have the updated pump housing so it won't wear through again. I did the removal and replacement myself and it took about an hour and a half to remove. Not hard to do at all, just make sure you get the wiring disconnected before you start moving things around, the sensors are easy to break.
Since the truck was down for five days I also removed the trans to take care of a small leak in the bell housing too. It's been a week now and all looks good, no leaks, not even the epoxy fix.



So MY JB Weld fix is certified by GM To be good for a 2 year warranty?

I have been running mine for nearly 3 years with great success, so I guess I should be working for GM as an engineer............

hey can i just take off the back cover with it on the truck or do i have to remove the whole transfer case from the rig?


You have to remove the case, to get to the snapring.

Look at the instructions here.
http://www.dieselplace.com/forum/showthread.php?t=140732

Also on one of the last posts, I listed Merchants Link for a GREAT Breakdown of the case, it is like post 70.

actually tolli i printed your instructions as well as MA's

my clip is worn through do i need to get a new one? ive got the merchant automotive kit. (the clip in the spot where the pump wears through)

With the M/A Kit, there is NO NEED for the clip!

That is according to Eric at Merchant auto.

FRIGGIN SWEEEEEETTTT!!!!!!!!!
its 7:20 in california and still light outside maybe i can get this done today!

http://img41.imageshack.us/img41/5243/img9146j.th.jpg (http://img41.imageshack.us/i/img9146j.jpg/)

I girss you are finished, and swapped the case half?

I would have kept the case half, and JB Welded it, that is what GM is doing these days........but they give a 2 year warranty on them.

I have burned one, MAN That thing gets hot and bright!! Did yours ever catch fire? you know the actual case burning?

Ive still got it i just threw a little race gas on it for a nice little photo OP. Signal flares have magnesium in them too thats what makes them so bright. but yeah getting the thing back into the rig was a B!t@* !!!

Why are u gettin rid of your truck Tolli ?!

Nope, keeping it, I do not have that much in it, and tradin it is not an option, and no one wants it.

So with a Brand new set of injectors, I think I will keep it for another 150,000 miles or so.....