Transfer case fix?

[DaveNY]

OK at 255,000 mi I have the wear through on the rear case on the auto trac TC.What is the best fix? A new OEM housing with the fix plate or an aftermarket aluminium thicker housing. Or something else out there that is best.
Thanks Dave

[crashz]

I put a used case in my 04 after having that issue. If you decide on a new case half, I'd get a re-build kit along with the pump rub kit. I think I'd probably go with the stock case half to ensure a good fit.

[DaveNY]

I ordered an aftermarket aluminium rear case and a wearplate, Only lost a couple of oz of oil when i noticed the leak. The case is working fine, smooth and quiet. Drained and refilled no metal or dirt. Hope the case fits (Dorman), Did not want to install another magnesium case.Thanks for the reply, I will let you know how the new case fits.
Dave

[More Power]

Because magnesium is harder to work with, I wonder why GM chose it over aluminum for the transfer case, and whether there's any strength difference between the two alloys used...

I also wonder what alloy was used in the 208 txfer case, like those found in the 1980s trucks? One I had at the time developed a crack that leaked ATF.

[DaveNY]

I "Wonder" about a few things in these trucks. Like how long do they let a known defect continue without even a thought about change? Basicly a good vehicle. The Boys in Mexico did a good job puttin it together, The drive line is as strong as they come. The few cronic problems common to these trucks are absolutly easily reversable.Somwhere the ball was dropped. How many perfectly good Injection Pumps were replaced due only to the stuborness of GM to move the FSD, or install a slightly thicker pump plate in the rear housing of the Transfer Case. Just Puzzles me!!!

[DaveNY]

Sorry so long but was in the Turks&Caicos Islands on the beach and let the truck sit.But the Dorman piece fit perfect, came with clips and everything else needed to fix the problem.
Got it from Rock for about $148.00. Sturdy Aluminum.
Dave