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2500HD/3500 HD Trucks & Drivetrain Discussion Forum for the 2001 & newer 2500HD/3500 Trucks, Transmissions & Drivetrain

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Old 07-02-2009, 05:14 PM
Hawker Hawker is offline
Join Date: Jun 2009
Posts: 8
Default part numbers

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.
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Old 08-06-2009, 09:06 PM
mattb5150 mattb5150 is offline
Join Date: Jul 2000
Location: Gilroy, California, United States
Posts: 396

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


1993 K2500 HD 4x4 - SOLD

2003 GMC K2500HD SLT EXTRA CAB/SB DMAX/ALLI, Bilsteins, Sulastic Shackles, Pitman & Idler braces, KD Headlight Harness, CAT filtration, Lift pump w/KD harness, Denali Door handles, Yukon exterior mirrors

2003 Yamaha Grizzly 660 Stoopider FAST

1996 VW Passat TDI 48mpg - SOLD
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Old 11-27-2009, 02:37 PM
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More Power More Power is offline
Join Date: Feb 2000
Location: Big Sky Country
Posts: 10,455

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....

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Old 11-30-2009, 09:16 PM
mastertech mastertech is offline
Join Date: Nov 2009
Posts: 19

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
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Old 06-18-2012, 06:20 PM
SoTxPollock SoTxPollock is offline
Join Date: Dec 2004
Location: Texas
Posts: 679

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?
02 2500HD LT D/A SB CC 4X4 BLACK, Westin stainless nerf bars, BW GN Hitch,Racor 60S post oem fuel filter, Oil Guard bypass engine oil Filter. All synthetic fluids. Kennedy boost valve, edge, Modified air intake,EGT & Boost digital gauge,TransferFlow combo fuel & tool box, Air Lift Suspesion Bags Rear & compressor with remote, Bilsteins front & rear, Frontier front replacement bumper.
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Old 08-10-2013, 05:36 PM
TheAmigo TheAmigo is offline
Join Date: Oct 2001
Location: Mobile, Al. USA
Posts: 45
Default Ongoing info...

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.
2002 2500HD 4X4 CC SB
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Old 08-11-2013, 04:33 AM
jbplock's Avatar
jbplock jbplock is offline
Join Date: Mar 2000
Location: Owego, NY
Posts: 1,924

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..
03 2500HD D/A CC/SB/4WD,OilGuard, MegaFilter,LiftPump/PreFilter, Bilsteins,RetraxRollTop,J&J Boards,Coolant Filter,AlliDeepPan,FastIdle,AllHeadLightsOn,
98 K3500 6.5,SOLD

Last edited by jbplock; 08-11-2013 at 05:31 AM.
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