I found a small pinhole in the side of my transfer case found out it is a common problem caused by the failure of a anti rattle clip inside the case. When it fails the oil pump "rattles" on the case and in time wears a hole in it. So out it came and I repaired it last night. It wasn't too bad a job and I had it done in less then 4 hours. The picture clearly shows where the clip has broken (right side missing) and the small groove cut into the case by the oil pump. The broken clip was stuck to the magnet at the bottom of the case and everything else looked fine. The new part looks identical even tho I was told it has been improved.

Improved huh? That would be nice. Man that looks weak.

i have had the same problem as you mentioned, dealer has changed a dozen or so, cost of a rebuilt one is 2grand installed, keep us informed if this works for you,thanks

Does this happen on both the push button and manual shift transfer cases or is it just specific to one? Where there specific years that this effected as well? I am just wondering that way I can make sure if I need to watch out on my truck.

William

new parts have not been improved at all, at least not the housings. I heard they changed the pumps some, but havent seen a new one yet.

Not a bad repair, if you catch it before you loose all the fluid and burn it up.

Fred, your t-case is ready to go.....call me

will do in the am

I had the same problem, I patched the hole with metal epoxy from the outside earlier this summer and later I had to open the case because of a broken 4x4 fork. I couldn't afford the back half of the case at that time so I patched the unwanted slots from the inside again with metal epoxy and made myself another clip wich I think is stronger. It's been almost 10,000km since that "repair" and I have no leak yet.

Here's the thread wich spans from 163,000km in mid-July to 172,000km in mid-September. I'm now at 181,000km in mid-November.

This thread as almost the same photo as you ans a few more.

http://www.dieselplace.com/forum/showthread.php?t=37492

Of course, by the time this happens, everyone is outside the waranty ... This is a major defect IMHO.

autogyroflier: on you photo, you seem to have some kind of defect further down the case in line with the clip. Is it just dirt or is something wrong?

Good luck to all.

I take it this happens on any year with either the push botton or floor shifter.

William

That seems to be the "case":rolleyes:

ERIC:

thanks for the transfercase, truck is up and running again, i sent the other one back to you, will call soon to take care of the money part

looked to have a good size hole in the thing