Transfer case leak repair?

[Hawker]

Best if you call the dealer with your vin number. From there they can look up you transfer case. The boot clips and gaskets differ on a few of them. Lucky I was at the dealer I bought the parts over the counter and carried them to the mechanic saved me naywhere form 15% -30% parts markup.

[mattb5150]

Bought the new case half and had it installed today. I have the old case half if anyone would like to have it welded.

Matt

[More Power]

I received an email from a 2500HD owner recently who's transfer case also suffered from the wear-through leak failure. He had read this thread, and ordered a replacement rear case half from one of the vendors mentioned - along with the new aftermarket part that will prevent the wear-through from re-occurring.

Problem was, his truck was not powered by a Duramax - his truck had a gas engine. The gas powered trucks use a 261/263 transfer case, but have a different rear case half because the rear driveshaft yoke is smaller (probably a 1350 u-joint, instead of the 1410 used behind the diesel).

Just an FYI....

Jim

[mastertech]

The case of the wear is from a keeper that is attached to the oil pump that is in the tcase it vibrates and cases a hole in the case the fix is a new half and a readvised keeper to correct the concern or problem

[SoTxPollock]

Anyone who used JB Weld on the transfer case, I'd like to know how long you've been running like that and how long do you think that fix will last?

I spotted a leak on the garage floor and started watching it for a while and finally last week-end found the wear thru hole about say 1/8" wide and 1/8" long. Needed to use the truck, so I went for the JB weld fix. I bought the one that said it's good to 600 degrees F. so I know it won't turn loose because of heat. I cleaned the area with denatured Alcohol and use an old tooth brush on my electrice tooth brush. Kept reapplying the Alcohol while running the tooth brush over the area till it was nice and shiny. I then took a dime and ground it across to where it would fit in the area, thinking it would supply some reinforcement in the long direction of the dime agaist where the oil pump tab was wearing thru. I stuck it on with the JB weld and then apply liberal amounts of JB weld to fill in the area and let it sit up for 24 hours. You have to know it's there to even see it, it looks really good. The tensil strength of the JB weld is shown as 3600 lbs. so it should hold the dime in place and seal the hole, I think for a long time. I'll continue to run it that way until I'm sure it will hold up under heat up and cool down cycles. I don't know off the top of my head what the coeffecent of thermal expansion difference between the steel repair and the magnesium case is that's the unknown factor for me. Gonna have to look that up. If it will stand a few million cycles without failure, then I'll probably let Kennedy put one of his inserts in there and really know I've solved the problem. Again has anyone had a failure of the JB Weld fix? What epoxy is GM using on those replacement items?

[TheAmigo]

After having the first pinhole patched by the dealer it's still going strong about 4 years later. However, I just found a 2nd pinhole. I'll be plugging it with JB weld too.

[jbplock]

A few years ago I reinforced the transfer case on my 03 by applying some stick-epoxy putty to all the pump-rub wear points. It wasn't leaking at the time but I thought making the areas of the case that wear through about 3/8" thicker could prevent a leak. At 103kmi so far so good..