Transfer case leak repair?

**tufcj** · 07-12-2007, 08:32

Slid under it on Tuesday, after recovering from the trip on Monday. Pulled the fill flug on the t-case, and put in a little less than 1.5 quarts of ATF, so it wasn't completely empty, but close.

Sprayed the underside with super clean and pressure washed it down. Drove it to work on Wed-Thu, and I do see a couple of drips where I park it, but not much. No noise, so hopefully the case is OK. I didn't notice any fluid on the tailgate when I arrived in Denver, only when I got back to Chicago.

The next questions.

Can the back half be changed in the vehicle, or does the case have to be pulled?

If I have to pull the case, does the crossmember for the torsion bars have to come out?

Best place to get the case and the pump upgrade that's listed here.

I've done a couple of 235s from Jeeps, so I'm no stranger to t-cases. If I have to do this, I'd just like to do it once, do it right, and be done with it.

Bob
tufcj

**More Power** · 07-12-2007, 09:43

It might be possible to pull the rear case half only, without pulling the entire transfer case out of the truck, but it would actually make more work for you. Disassembly and then re-assembly just about has to be done with the transfer case sitting vertically on its front flange.

Rear case halves are available, and I'd install the Merchant pump upgrade to prevent this from happening again.

Jim

**Kennedy** · 07-16-2007, 08:32

I've done a half dozen or so of these now as preventive maintenance. All had the OE clip still in place and no apparent sign of wear. For the price ($50) for the little wear plate I will not drop a transfer case without installing one.

**Inspector** · 07-16-2007, 09:39

I have had the T-case on my 93 apart a couple of times. It is not rocket science. These are easy to repair. As MP said the case needs to be verticle so all the shafts stay aligned when putting the back case back in place. If you are going into the case any farther than the back case you will need a good set of snap ring pliers.
My 03 hasn't shown any signs of leakage as of yet but it is somthing that I keep a close eye on.
Denny

**Ranger354** · 12-10-2007, 12:26

After searching for two days and 2 qts of fluid I found a pin hole in the side of me T case today. Dealer said the swap out will be a little under two grand. I talked with a reputable trnamissiion shop and they just happen to be doing the same thing on a vehicle. the Trany shop price was a little over 2 grand.

Next time I buy a chevy (if I buy a chevy) I will get an extended warranty. This is BS. Two front hubs in the last three months and now a T-case with less the 90,000 miles.

They sure make Ford better and better looking....................

**More Power** · 12-10-2007, 20:33

I was under the impression that welding magnesium was not possible, I saw recently a discussion about welding a variety of materials, which included magnesium. So, I did a google search, which would suggest it is possible when using a TIG welder. If you can weld magnesium, it would reduce the cost of a leaking t-case considerably.

Any welders in the group who know more?

Jim

**a5150nut** · 12-10-2007, 22:48

Originally Posted by More Power

I was under the impression that welding magnesium was not possible, I saw recently a discussion about welding a variety of materials, which included magnesium. So, I did a google search, which would suggest it is possible when using a TIG welder. If you can weld magnesium, it would reduce the cost of a leaking t-case considerably.

Any welders in the group who know more?

Jim

I remember when I was a kid and the local fair was in town. The local volunteer fire dept. was putting on an exhibition on magnesium fires. Someone tried to put it out with water when it got into their barrels of extra material. Kinda reminded me of the 4th of July!

But I did have a neighbor who claimed he had welded aluminum to stainless. Had to use a vibrating table at just the right frequency. So I guess anything is possible.

**Ranger354** · 12-11-2007, 18:02

Was told today (after I picked up my truck) that one the welders at our Plant had a Bad Ass machine that could weld anything. Sure wish I had known sooner. I would have let him try. I heard that he has welded on many trannies and engine blocks.

**Ranger354** · 12-12-2007, 19:38

Well I made it all of 30 miles and heard some noise. On the way home from work i got about a mile and lost power. I think the brand new second hand rebuilt T case blew. It sits tonight at the dealer. Guess I will know more tomorrow.

**Ranger354** · 12-18-2007, 09:22

I got my truck back from the dealer's shop yesterday. They gave me a Ford CC 1/2 ton to drive over the weekend. I will never buy one of those. Anyway, so far so good. I plan to put some miles on the 2nd new rebuilt T case tomorrow and see if she will hold up.

Been looking for any service bulletins on the (2004) T Case.

**Willcoc** · 12-18-2007, 10:24

Earlier this year, the pin hole developed in my case. Ordered the parts and had a local mechanic do the work. We did install the Kennedy part to keep it from hapening again. Just to test, I took it to a facility that does mag casting work. Since the casting are not perfect (fan blades), they do weld repairs. He was able to seal the hole in the case. Unless you know where to look, don't even notice it. If anybody is intersted, cover shipping and it is yours... had ~96K miles when this took place.

**italian ice** · 12-26-2007, 18:57

We have a 2003 Yukon XL, 2500 6.0 used for towing our offshore boat. The truck has 62,000 miles, it was used as my wife's daily driver for the first three years owned. Now it just goes on vacations, boat towing and snow storms.

About 3 weeks ago I discovered a noise, sounded like a dry U-joint. On 12/14 the local Chevy dealer accurately diagnosed the problem and told me that they had seen the problem before, loss of fluid due to hole caused by internal failure. "Needs new case, estimate to start is $1,326.00 estimate doesn't include internal failure may be higher once taken apart". The service tech said it could be a couple hundred more, depending on what they find on disassembly.

I made a service appointment for Monday the 17th. at the GMC dealer where I purchased this vehicle (and three others in the past 6 years). Over the weekend I did my research and found this thread. I printed the entire thread for the Service Manager and took it and my truck to my dealer on the 17th. I also called GM Customer Support the same day, and explained the entire story and as much as I could relate about all 30-some others of you in this thread who had the same issue. GM Customer Support rep told me he would call me on Tuesday afternoon with a response, but no promises given. By mid-day on Tuesday the Service Manager called to tell me the repair would cost $3,400. I knew he had been in contact with GM Customer Support. He went on to say that it would all be covered except for the Illinois Sales Tax on the parts, or $100 - $150.

The Service Manager mentioned how well maintained my vehicle was and it seemed that we recently started getting the vehicle serviced elsewhere. He said he wanted us back as a service customer and "recommended" the 60,000 mile maintenance package. It was hard to say no when he just told me my repair bill would almost be paid in full. The parts were ordered and it looks like I'll be lucky if I get it back by Friday. More likely next week after the holiday.

The GM Support person said it was good that I called while the truck was there and they could work directly with the dealer before the repairs were completed.

I'll post an update when I get the truck back.

**Ranger354** · 12-26-2007, 19:43

What number did you call at GM. Maybe I can get back some of the $2,200 I spent on a rebuilt one at the dealer here.

Hope all goes well.

I got a letter in the mail this weekend stating that some GM customers have had problems with the speedometer and guages. If I have a problem with these items on my truck I was to take it to the dealer along with the letter. Well, I have not had any problems with the speedometer and guages, but I have the front hubs.

Wonder when I will get the front hub letter????????

**italian ice** · 12-28-2007, 13:42

Ranger, the number I dialed is 800 462-8782. Best of luck to you.

**More Power** · 12-28-2007, 16:14

Originally Posted by Willcoc

Earlier this year, the pin hole developed in my case. Ordered the parts and had a local mechanic do the work. We did install the Kennedy part to keep it from hapening again. Just to test, I took it to a facility that does mag casting work. Since the casting are not perfect (fan blades), they do weld repairs. He was able to seal the hole in the case. Unless you know where to look, don't even notice it. If anybody is intersted, cover shipping and it is yours... had ~96K miles when this took place.

Thanks for your post. Could you list the contact information for the shop that does the magnesium welding? Thanks!

Jim

**Kennedy** · 12-28-2007, 16:29

I finally got around to listing a details page for the plate that I sell. The mfr states that JB Weld does well although I'd prefer a new or welded case. If I were to do the JB thing, I'd be sure to extrude some through the hole so there was a bit inside and out to hold fast.

Plate details:

http://www.kennedydiesel.com/detail.cfm?ID=511

**linchhummmer** · 01-13-2008, 13:10

auto track ii is just blue dexron so when your seal gose out you can see it turn red it dosent matter what you put in it dexron is probablye a little cheaper

**linchhummmer** · 01-13-2008, 13:18

the exact same thing happed to my 01 lb7 i got a small hole in the tcase and the fluid leaked out and the truck sat in the shop for like a month before i went and picked up and just drove with some jb weld over the hole but they told me that sh!t off the road hit it and did it, it was probably the same thing that happened to yours that happened to mine

**DmaxMaverick** · 01-13-2008, 13:49

Originally Posted by linchhummmer

auto track ii is just blue dexron so when your seal gose out you can see it turn red it dosent matter what you put in it dexron is probablye a little cheaper

How many TC's do you want to buy? Bad advice. Autotrac II fluid IS NOT just blue Dexron. The Autotrac TC's have unique requirements of the fluid. Unlike traditional TC's, they have active syncro's and slipper clutch friction surfaces. Some premium synthetic ATF's claim to be compatible with Autotrac II fluid, but most do not. Put Dexron in your Autotrac if you want, but don't advise others to do the same unless you are offering a warranty with the advice.

**fats chevy** · 01-18-2008, 02:21

I know of a dealer that does 2 a month. I got my hands on service information (bulletin), after I replaced the rear case. '98-'07 equipped with New Venture Gear TC RPO NP1, NP2, NP3 ,NP4, NP8. Will attach Doc. later.

Originally Posted by linchhummmer

the exact same thing happed to my 01 lb7 i got a small hole in the tcase and the fluid leaked out and the truck sat in the shop for like a month before i went and picked up and just drove with some jb weld over the hole but they told me that sh!t off the road hit it and did it, it was probably the same thing that happened to yours that happened to mine

Thread: Transfer case leak repair?

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Welding Magnesium?

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Ok, 2nd brand new rebuilt

Anybody need a repaired T-case back half?

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Can't beleive there has been no recall for TC....hole

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