Worn bearings in the mainshaft of the Xfer case.

 

Nothing, the reluctor gear, should not come into contact with the speed sensor. If that has happened there is some internal wear that is allowing the reluctor to move and contact the speed sensor. Has your transfer case ever run low on oil?

 

transfer case oil level

The transfer case may have run low on oil... the previous owner just replaced the rear housing before I bought the truck due to the well-known wear through problem. It may have run low on oil at that time.

 

That could very well be your problem. He may have cheaped out when he replaced the rear housing and left damaged internals for someone else to deal with. If you manually push up or down on the shaft where it comes out of the back of the transfer case is there any movement(play) ?

 

This seems like you're on the right track. I'm going to check this out as ASAP. I'm moving between cities, to Rdmonton in a couple of days so I'm packing like mad right now

 

Maybe your Edge tuner is causing problems? Just a thought..

 

I took a quick look at the transfer case today and it looks like it's leaking oil between the transfer case and transmission, supporting the theory of worn out bearings and seals. I'll have to check it out more once I get to Edmonton. Hopefully it won't wear out the rear seal on the transmission before I can get it fixed.

 

Replaced transfer case with rebuilt unit; problems solved

 

Just wondering if you took a look inside of your old transfer case?

 

I took a quick look at the transfer case but the shop was closing as they finished my truck so I didn't have much time to poke around. I didn't get enough time to even figure out which one was the reluctor wheel let alone check for wear on it. The case was leaking however, so there was a no good seal at least, and likely shot bearings.

Also of interest, after a couple of days THE PROBLEM CAME BACK so the 'fix' may have just been a coincidental lapse in this intermittent problem. I'm going to be looking into other solutions as the problem is getting worse and affecting me at much lower speeds now. I just moved cities and started a new job only to find that my new Edmonton roommate is experimenting with teenage crackwhores at home; also my dad died last week. Things might take a while to settle down so that I get this truck figured out. :

 

wow

 

Also, I've taken the Edge out since I don't like the way it delivers its extra power. Thinking about Killerbee tuning if anything. The problem is unchanged with the Edge gone.

 

Hi guys i'm going to finally close up this thread by posting how i fixed the problem. The wiring harness leading to the speed sensor had a break in the wire inside the insulation, just a couple of feet away from the sensor. I replaced this wire and the problem is gone.