2005 LLY 2500HD Trasfer case life - Diesel Place : Chevrolet and GMC Diesel Truck Forums
 
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Duramax Second Generation: 2004.5-2005 (LLY) Discuss the second generation (2004.5-2005 LLY) of the 6.6L Duramax diesel engine & associated components. 2006 LLY engine discussion belongs in Third Generation forum due to the differences of the 2006 LLY and the 2004.5-2005 LLY. Engine related discussion ONLY.

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Old 08-08-2019, 12:23 AM   #1 (permalink)
Polish Eagle
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2005 LLY 2500HD Trasfer case life

Orig owner, I got 175k on my pick up , h20 pump at :125k complete brakes ,shocks at 100k , now new brakes all around atc175k questionive heard the transfer case get a leak in the housing because of a pump vibration wear , I got the anti rub plate kit. Just gotta put it in , is it a big job ? Do I have to replace chain in transfer case? Etc Does the pump rub against case to make hole even if it's not in 4wd ? What's the average mileage these transfer case springs a leak can I alum weld case ?

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Old 08-08-2019, 02:16 AM   #2 (permalink)
jake111
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Quote:
Originally Posted by Polish Eagle View Post
... ive heard the transfer case get a leak in the housing because of a pump vibration wear , I got the anti rub plate kit. Just gotta put it in , is it a big job ?
There are step-by-step instructions, and videos. "Big"? Some people don't think so. There are tricks you need to know for removing the tail section (tricky snap ring). I had my brother help me but (1) he once had his own shop and now teaches auto mechanics, (2) he had already done his so he knew all the tricks, and (3) he had built a wood jig to hold the case while working on it.

Quote:
Originally Posted by Polish Eagle View Post
Do I have to replace chain in transfer case? Etc
Not unless it's worn out for other reasons.

Quote:
Originally Posted by Polish Eagle View Post
Does the pump rub against case to make hole even if it's not in 4wd ?
Yes

Quote:
Originally Posted by Polish Eagle View Post
What's the average mileage these transfer case springs a leak can I alum weld case ?
I would say the range is 75k miles to never, with 150k-200k miles being common. The tail section is magnesium. There are after-market aluminum sections available, but they aren't needed unless the section is damaged, or the tail shaft bearing is sloppy (or you can just replace that). Some have "liquid welded" where the pinhole develops and had it last "forever".

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Old 08-08-2019, 04:20 AM   #3 (permalink)
davester
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It's pretty straightforward to do. I did mine prior to a hole being worn in the case, and put in the pressed metal plate.


My case had over 200k on it, so I also replaced all the bearings/seals/bushings in it. If you do this, make sure you get the right kit for it, as there are multiple "versions" of the TC, and you would have the NP261XHD(manual shift) or NP263XHD(electric)


Besides the pump rub fix (plate, or billet pump or replacement tail housing), you also need sealant for the case halves (I used Permatex Anaerobic Flange Sealant, worked fine for me).


Some tips:
-clean out the bottom of the TC case, magnet & oil pickup tube, as the sealant that squeezes out inside the case will have come off and is sitting down there trying to plug that pickup tube
-don't overdo it with the sealant, as using more just results in more being squeezed out, and falling down and trying to plug that oil pickup tube
-maybe put some grease inside the lip of the seal at the rear of the housing, to keep the spring in it in place, as if it pops out when you reinsert the yoke, it'll slowly leak out that seal
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