Transfer case overhaul – general information
Overhauling a transfer case is a difficult job for the do-it-yourselfer. It involves the disassembly and reassembly of many small parts. Numerous clearances must be precisely measured and, if necessary, changed with select fit spacers and snap-rings. As a result, if transfer case problems arise, it can be removed and installed by a competent do-it-yourselfer, but overhaul should be left to a transmission repair shop. Rebuilt transfer cases may be available – check with your dealer parts department and auto parts stores. At any rate, the time and money involved in an overhaul is almost sure to exceed the cost of a rebuilt unit.
Nevertheless, it’s not impossible for an inexperienced mechanic to rebuild a transfer case if the special tools are available and the job is done in a deliberate step-by-step manner so nothing is overlooked.
The tools necessary for an overhaul include internal and external snap-ring pliers, a bearing puller, a slide hammer, a set of pin punches, a dial indicator and possibly a hydraulic press. In addition, a large, sturdy workbench and a vise or transmission stand will be required.
During disassembly of the transfer case, make careful notes of how each piece comes off, where it fits in relation to other pieces and what holds it in place. Note how parts are installed when you remove them; this will make it much easier to get the transfer case back together.
Before taking the transfer case apart for repair, it will help if you have some idea what area of the transfer case is malfunctioning. Certain problems can be closely tied to specific areas in the transfer case, which can make component examination and replacement easier. Refer to the Troubleshooting section in the introductory pages of this manual for information regarding possible sources of trouble.