haha, thanks for the tip... I cycled all the modes, then each one a little blip of the throttle. Drove one mile. It works like a CHAMP!
I'll put it in 2hi and drive about 10 miles. I do notice the motor is under a bigger load. I'm assuming that 4wd is partly engaged. However, tires don't bind when I turn which is good.
Build was SUPER easy. You were correct. I just had to find time to get to it. I built it up once... Then RTV'd it only to find I forgot a snap ring! I tore it completely down and reassembled it again in like 30 minutes.
The only blooper (separate post) was a efd up the encoder motor. Had to take it apart, pull the motor, and spin the shaft to get it back to neutral position. PITA I was almost done swapping the case after 9 hours of work... Only to have that encoder motor give me crap and it take another 9 hours to figure out.
Few notes. At 250,000ish miles the TX case looked like NEW inside. It was MINT, clutches were in spec, only issue was the pump rub. Had I not done this rebuilt, it's for SURE it would have rubbed through the case. A person maybe just as well to just put in a case saver and throw it back together. Otherwise wasn't too expensive to buy the rebuild kit. Chain IMO is a waste of money. The factory one was in perfect shape, no slop at all... only slop was a little from the carrier bearings on the shafts. Once I put new bearings the chain had no slop at all. I saw a few people on YouTube checking chain slop w/o supporting both sides of the shafts in the case. You cannot do that... It'll look loose that way. Once the case halves were temporarily put on it had no slop in the chain. The light noise when you spin the shafts is the apply hub (I think that's what it's called) touching the shift fork. It's normal and not the chain. The upgraded Raybestoz GPZ clutches were cheaper than the factory ones (I didn't want Chinese spec stuff they were not much more than those though). Hardest part was just getting the case out off the truck. I don't know why anybody would not try rebuilding one of these on their own. Was SUPER easy, just be careful you pull the encoder motor in NEUTRAL (or 2hi?). To put in neutral, push 2hi and 4lo buttons w/ trans in neutral for 10 seconds. Then pull the encoder motor and next the tx case. I pulled the encoder motor because I was worried about smacking it on the ground / breaking it otherwise.
Thanks for all the help! Stoked to have a good as new (better than new?) transfer case. Has upgraded clutches, case saver, and all new perishable parts replaced...