Recommendation for a Transfer Case Remanufacturer

[bsamole]

The transfer case in my 1999 4x4 Tahoe sounds like a rock crusher when in 4 Hi. I want to replace the 246GM (NP246) with a remanufactured case. During my research I discovered quite a few T-Cases are remanufactured in South Carolina. Any recommendation and experience will be appreciated.

 

[rockola1971]

I personally rebuild my own. Theres not much to them and really the only "uncommon" tools needed that not everyone has is internal/external snap ring pliars and bearing/seal pull/install tool set. Parts are not expensive. There are tons of youtube videos that show step by step. Or you can just goto ebay to find a rebuilder that sells them by using search term "np246 transfer case". Looks like they run around $700.

 

[Big Mama]

Powertrain Products has a nationwide warranty

 

[bsamole]

I've looked at the YouTube videos on rebuilding a transfer case and I agree it doesn't look that complicated. I have a necessary tools however I will not know if the TC was rebuilt correctly until I reinstall it. I do not want to do the R&R twice.

 

[rockola1971]

I've looked at the YouTube videos on rebuilding a transfer case and I agree it doesn't look that complicated. I have a necessary tools however I will not know if the TC was rebuilt correctly until I reinstall it. I do not want to do the R&R twice.

There truly is nothing much to them. They arent even remotely as complicated as a transmission. The videos on youtube are more than enough for the beginner. Hell they dont even have seals that have to be sized like a transmission does. Seriously if you can do a complete overhaul brake job you can do a transfer case. Check your fluid level...i bet its low and I bet you have a pinhole on the rear half of the case passenger side.

 

[George B]

I would totally do it. I replaced the case half on my last one with a part from rock auto and installed the pump guard plate. It was easy as pie. Taking the case out was harder but I didn’t even have to take out the cross member or support the trans.

 

[bsamole]

Okay guys, I'll give it a shot. Hopefully the lead time on getting replacement parts will be short.

 

[rockola1971]

Okay guys, I'll give it a shot. Hopefully the lead time on getting replacement parts will be short.

All of the parts can be had on ebay and rockauto in less than a week. If I were you I would expect to have to replace the rear half of the case and install pump rub plate to fix the known GM issue with these cases. Will need a seal and bearing kit, new chain and clutch set if you have auto 4wd option. Get snap ring pliars that have a long reach. Dont forget fluid and soak clutches in the fluid if you have the auto4wd option for a couple hours before install. You will need a torx bit set to take case apart. Inspect hard parts for damage and replace as neccessary. Any questions, just post up here and we will get you straight.

Your case probably either has a bad bearing (low on fluid because of pump rub hole) or stretched chain smacking inside of case which will eventually chew a whole through the case.

 

[bsamole]

Thanks for a list of parts needed and probable sources. I will post the results.

 

[rockola1971]

Thanks for a list of parts needed and probable sources. I will post the results.

https://www.drivetrain.com/parts-catalog/transfer-case-replacements-and-parts/np246

BK351 was part# for seals and bearings that I used for my last 246E rebuild. Shop around.

https://www.amazon.com/Chevy-NP246-Transfer-Rebuild-BK351/dp/B01BZ9N2PY

 

[bsamole]

Thanks so much to Rockola1971 and George B for your input.

I am ordering hopefully all of the needed parts in advance in order to reduced down time. I have ordered from Amazon the BK351 transfer case rebuild kit, and ACdelco 10-4017 Transfer Case Fluid.

I plan on ordering this reinforced rear case half
(C30605) from Amazon. Is this the best choice?

https://www.amazon.com/gp/product/B07JCLT4WB/ref=ox_sc_act_title_1?smid=ATVOFOAFVEK8V&psc=1


Is it usually necessary to replace the clutch set since the shimming tool seems quite expensive.

Is there a preferred brand for the chain?

Are all necessary gaskets included in the BK351 kit?

Thanks for sharing you knowledge!

 

[rockola1971]

The case you linked will do but dont forget to get the pump rub plate. https://www.amazon.com/Process-Transfer-Case-Pump-Plate/dp/B00BYF8KO8/ref=sr_1_1?crid=Q60M6CRTF1G6&keywords=np246+pump+rub+kit&qid=1583114183&s=automotive&sprefix=np246+pump,automotive,172&sr=1-1 Shop around. Something along the lines of this for the chain https://www.amazon.com/NP246-Transf...p246+chain&qid=1583114415&s=automotive&sr=1-1

As far as the clutches go if yours has auto 4wd just toss a new set in there and dont worry about the shimming. Just install all the factory shims back in and be done with it. When you see how they go together in the drum and the factory play you will see what I mean. Its nothing to worry about.

There is only two gaskets on a NP 246 TCase. The one that is at the middle where the case halves meet. You can use RTV if you want. Bearing and seal kit might have it in there and the one at the very front where tranny bolts up. That one is shown in the BK351 kit, its the round gasket.

 

[George B]

I used a US Standard Gear case half from Rock Auto. Worked well.

 

[bsamole]

Thanks guys. Mine does have auto 4wd so I will do as you suggested and use the factory shims. I will also check out the offerings from RockAuto and other sources.

 

[bsamole]

I split the case and discovered the oil filter was completely clogged solid on both sides, the magnetic washer was also clogged and difficult to remove, 13 loose ball bearings and part of split ring loose in the case, another bearing had 13 ball bearings in the race without any metal separators and the oil pump wear clip is missing.

Is this type of damage normal?

Should I continue with the rebuild?

If so

How to test the planetary assembly it appears okay but I have never looked at one before?

Is the oil pump wear clip necessary since I have a pump rub plate to install?

Do I grease the bearings or splash some transfer case oil on them?

 

[rockola1971]

There were 13 ball bearings rolling around in your case? If so it sounds like your case was starved of fluid. (leak). What was its level at when you drained it? Planetary assembly in a Tcase? They are in the rear of a transmission, not a Tcase. Yes the clip is necessary. Its what probably ground up and attached to the magnet or in your clogged filter. Inspect all gear teeth for broken or chipped teeth. Replace gear if any are. Used good hard parts are all over ebay and are cheap enough. Nothing wrong with using used hard parts for a Tcase.

 

[bsamole]

There was oil in the case with no pin holes or leakage. I agree the clip must have come loose, ground up and caused the clogged filter and lack of oil to the bearings. Especially since it appears the clip has been updated with GM89059653. I'll check for chipped or broken teeth. I gleaned the word planetary from the Autry Enterprises diagram on areds.com however other sites name it annulus gear. Thanks for all of your support. How do I lube the bearings on reinstall?

 

[rockola1971]

There was oil in the case with no pin holes or leakage. I agree the clip must have come loose, ground up and caused the clogged filter and lack of oil to the bearings. Especially since it appears the clip has been updated with GM89059653. I'll check for chipped or broken teeth. I gleaned the word planetary from the Autry Enterprises diagram on areds.com however other sites name it annulus gear. Thanks for all of your support. How do I lube the bearings on reinstall?

Bearings will be lubed by fluid in Tcase as soon as you fill it up after installation into vehicle. They do not need to be prelubed like cam/crank bearings. Dont forget to soak clutch plates in Tcase fluid for 4hrs+ BEFORE installing them.