Transfer case woes NP149

[01DenaliHiker]

So, I've finally accepted that I need to purchase a new transfer case. At least 1" of play all around from both shafts, hard acceleration produces the world's worst clunk on Earth followed by what sounds like grinding/clicking at first it seemed like the transmission mount, but that's nice and solid.

Previous owner apparently enjoyed running for however many miles without any fluid in it and I didn't discover it until after four months and about 5000 miles after the purchase. Just throws every drop out of the output seal.

Still runs and drives like a charm, just can't "get on it" without my truck sounding like it's about to turn inside out.

Any suggestions on a reputable place to order online? Only place that haunts my Google search is Monster Transmissions and Performance.

 

[Doubeleive]

POWERTRAIN PRODUCTS

 

[SnowDrifter]

Got my front diff from them. No complaints

 

[latvius]

When I was looking for a replacement transmission I read about a lot of bad experiences with Monster so I ruled them out - FYI.

 

[67RS427]

Do you know how to wrench or plan to remove it yourself? Just buy a new chain if it's AWD (BW4485)... You didn't specify what type of truck or T case you're talking about

 

[S33k3r]

Do you know how to wrench or plan to remove it yourself? Just buy a new chain if it's AWD (BW4485)... You didn't specify what type of truck or T case you're talking about

I was kind of curious how long it would take to look in the forums... Fortunately, this OP doesn't have a high post count, so I found it easily, in one of his earlier posts. It's a 2001 Denali.

But, yeah, either having the vehicle in his tagline or being specific in his posting would make it MUCH easier to help him.

 

[Doubeleive]

Do you know how to wrench or plan to remove it yourself? Just buy a new chain if it's AWD (BW4485)... You didn't specify what type of truck or T case you're talking about

lol, just buy a new chain? did you read the post

 

[67RS427]

lol, just buy a new chain? did you read the post

Depending on the transfer case, yes, a chain is all you need. Maybe a set of planetary gears if a tooth is broken. Since the OP didn't specify, I have no idea what T case he has. Most likely an older viscous coupling type. Still cheaper to rebuild it with $200 in parts vs $800-$1,400 for a reman unit

 

[01DenaliHiker]

NP149, yes, viscous type coupler. Sorry, it took about four tries to actually post so I guess I left a lot out from #1 to the #4 successful try.

If they're not much to piece together what does everyone think about Rigid Axle's rebuild kit?

Does it sound like it's just a chain? I've stretched chains in a transfer once before on an old bog truck and didn't have the play I do currently from my shafts in this one.

I'm pretty savvy around tools, so I apologise ahead of time for sounding like a noob with no purpose here.

 

[01DenaliHiker]

Only reason for worry is the way it seems to not stay stationary for lack of a better word. I bind like terrible at slow speeds at near full lock either way and under hard acceleration it literally feels like the transfer case is banging away, but if I grandma it right after it's just fine.

I thought I had u joint issues the way it would clunk into reverse and upon installing new ones realized my shafts wobbled inside the transfer case (can hear them knocking around) and leaked like a drunk after his thirty-third shot of patron with training wheels.

So with that information, willing to answer anything else if I possibly can; Does it sound like just a chain, or should I look into just doing a full overhaul and rebuilding it completely. I read something about the pump rubbing a hole into the rear case and highly doubt the previous owner did anything besides drive this like he stole it. No holes noticed, but just as a CYB (cover my butt) would a new rear portion be considered?

So many questions, I am a noob. No excuses after realizing what I'm typing here.

 

[Doubeleive]

if I drove around with no fluid in my transfer case for 5k miles I would be lucky if it didn't disintegrate and even if it didn't I wouldn't even consider trying to rebuild it. my last transfer case failure took the transmission out with it.

 

[01DenaliHiker]

if I drove around with no fluid in my transfer case for 5k miles I would be lucky if it didn't disintegrate and even if it didn't I wouldn't even consider trying to rebuild it. my last transfer case failure took the transmission out with it.

This makes two of us. I have no idea how it didn't detonate, especially with the previous owner. He was pretty clueless. There might have been a quart, if it's lucky. It just throws it all out of the rear seal from when I drained what it had and refilled hoping it would resolve itself. It did not, of course.

I absolutely have play within the case itself from the front and rear shafts. You can wobble the shaft like it has worn out ujoints, but all your motion is coming from inside the transfer case itself. You can actually lift the case up with your hand (forcibly) the amount of travel it has play wise on the shafts inside. With no motion on the transmission mount. Which was another hopeful thinking moment, but alas, not the case.

The fluid I drained did not smell burnt and I had no abnormal metal shavings beyond what you would expect after 225k miles and likely the first time in a very, very long time it's ever been drained. If not the first time.

I'm just going to have to find a day and pull it out and open it up. I'm actually excited to see just how terrible it is. Fingers crossed I'm left with something I can at least rebuild. Otherwise I guess an overhaul or whole new unit will be more fortune.

Just trying to get my ducks in a row currently.

Has anyone rebuilt the 149? What kit did you use?

The diagram looks pretty straight forward, I've rebuilt a handful of cases when I was younger and thought nothing could stop my truck while in high school.