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MarineGrunt
Enthusiast
Sep 8, 2012, 1:05 PM
Post #1 of 35
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Hole in transfer case
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Hope I posted in the right category. Well, the leak is not from the seal in the 2003 Sierra 1/2 ton 4x4 4.8. There's a small hole on the right hand side of the transfer case about 3 o'clock. I have heard that the cause could be from the pump due to a faulty clip design. I took a pick to the hole and it's worn thin around the hole too. Is there a recall for this? The truck only has 80k so could it be covered under warranty? If not, what is the proper way to fix it? Pull the case and weld it or buy a rear half? Is there a new and improved clip?
I can't seem to win lately. Being a Chicago Bears fan I'm use to it tho. Hope everyone's weekend is going better than mine! Are you guys sick of me yet?!!
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MarineGrunt
Enthusiast
Sep 8, 2012, 10:26 PM
Post #2 of 35
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Re: Hole in transfer case
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I found out there's an aftermarket wear plate that needs to be installed to prevent the pump from wearing the hole again in the future. I guess GM has some epoxy that they supposedly use to fill the hole. If I used epoxy I wouldn't be able to sleep at night. I'd constantly wonder if it took and if it would start leaking again. I'd end up checking the fluid every other day. Either that or I'd forget about it and all the fluid would leak out and I'd have to replace the whole transfer case. I found a new transfer case rear housing, rear bushing, seal, and wear plate on ebay for $220. So, looks like next weekend I'll be pulling the transfer case. Seems like a pretty easy procedure. Is there any certain parts I should replace or look for when I pull and split thetruck case? Any pointers?
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
Sep 9, 2012, 6:36 AM
Post #3 of 35
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Re: Hole in transfer case
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I can't suggest much for this MG. You seem to have found more on this issue already. Watching this though,
Tom
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MarineGrunt
Enthusiast
Sep 9, 2012, 8:52 AM
Post #4 of 35
(6248 views)
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Re: Hole in transfer case
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I found out that there was a faulty design in a clip that holds the pump motor in the transfer case. The clip will come loose allowing the motor to move back and forth. After awhile it eventually wears a small hole in the rear housing. The hole is probably an 1/8" diameter or just a tad smaller. I wonder if the pump is loose and I kinda sped up the wearing process when I jacked up the transmission a little trying to get the pan off. I'm just glad it was raining the other day so I was able to see the rainbow color of fluid on the pavement. I guess most are fortunate enough due to it only leaking when driving. Many end up having to replace or rebuild the whole t case. This is something that I will definitely mention to anyone I know that has a GM. It only effects vehicles with the push button 4 wheel drive years 1999-2007. It's recommended to pull the t case, remove the factory clip, and install the plate to prevent this problem from ever happening. Doing so will keep you from having to buy the rear housing or live with a jb weld patch. Some do the epoxy but that sure would make me nervous. People experience the hole in different areas so I would think it would be possible to have more than one area that's rubbed thin and a simple rock jumping up while driving could possibly finish off any other thin spot. Not likely but I think a few hundred bucks for the rear housing is cheap insurance. I thought about welding mine but I have never welded aluminum. I tig tubes at work so thought about pulling it and trying to tig it but wasn't sure how that would go. It was the last housing on ebay for the price so I just jumped on it. Maybe I'll try and weld the old one after I pull it just to see.
This makes me want to just go ahead with the spider gears so I know nothing else will go wrong for awhile. I want to get some pics of the chipped gears up first so I can see what you experts think. That might be a few days.
Thanks a million for this great forum. I could almost throw my manuals away!
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nickwarner
Veteran
/ Moderator
Sep 10, 2012, 4:40 PM
Post #5 of 35
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Re: Hole in transfer case
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I guess I should've read this thread before I posted to the other one. Since you already know how to TIG I think you could handle this. The case isn't under pressure. You need to get it fully degreased well but such a small hole should go easy. You'll need a TIG that can do AC and set the high frequency up a bit. Also bear in mind your voltage should be lower. Aluminum MUST be ground clean as hell to get the surface oxides off or you'll have a contaminated bead. Doing mild steel and stainless on TIG is as lot more forgiving. Go ahead and build up on it so you have a good base when you grind it back down to original thickness. Bear in mind you will also need a different shielding gas and tungsten for this.
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MarineGrunt
Enthusiast
Sep 11, 2012, 6:09 AM
Post #6 of 35
(6196 views)
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Re: Hole in transfer case
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I ended finding a new rear housing for around $200. I don't have a tig setup at home and the only shielding gas we have at the hall is argon. I have never welded aluminum so not sure how it would turn out. I may due more harm.than good.
Is there anything I should replace while I have the t case out? Front and rear seals I'm sure. How about the bushings? Bearings? Chain?
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
Sep 11, 2012, 6:32 AM
Post #7 of 35
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Re: Hole in transfer case
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Admit - I'm not equipped or skilled at aluminum welding which I call 'heliarching' (sp?) and would send that out myself. While ago a big buck BMW cracked oil pan with active leak till empty. Owner ran it too long and too low but not dead but was noisy. Called local place that does that. Damage was done and warned of the oil if a molecule was left could fail the patch work. Hmmm? Faked it best I could with magic junk you don't want to do and by second oil change then was quiet enough to go trade it in as owner bought a new one every few years anyway! Told that owner that it might not work and damage was near certain already. Duh - Engine not gearcase only.
In short - $200 for new sounds like a deal to me...........
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MarineGrunt
Enthusiast
Sep 11, 2012, 12:54 PM
Post #8 of 35
(6182 views)
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Re: Hole in transfer case
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I wouldnt know what to do with myself if i got a new vehicle eveey few years! Plus, you guys would miss seeing me around.  I think $200 is well worth the peace of mind knowing it won't leak.
I got the rear housing and wear plate in the mail a little bit ago. The only thing it has in it is a bearing. I have to install the bushing and seal. Not sure what else I have to swap over until I pull and split the case. The bushing and seal will be new. Just not sure what else should be new. I think I'll get started on it Friday evening.
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MarineGrunt
Enthusiast
Sep 11, 2012, 7:25 PM
Post #9 of 35
(6166 views)
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Re: Hole in transfer case
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Nick.....thanks for the tip on the seal on the other thread. I guess I should've just continued with that thread but wasn't sure since I had a new issue. The way you guys always follow all the threads I could've stuck with the one.
Here's what new parts I have so far for pulling the transfer case.
New rear noising
Output seal
Rear bushing
Fill and drain plugs
T-case to tranny gasket
Wear plate (part to take care of the pump rub)
Anaerobic gasket maker for where the case splits
Auto Team II Fluid
I'm also gonna order nickel plated slip yoke that JJ recommended and install it when I put it back together
Should I replace the front seal and bushing while I'm at it? Anything else that is normally replaced while it's out?
Thanks a million.
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nickwarner
Veteran
/ Moderator
Sep 11, 2012, 9:22 PM
Post #10 of 35
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Re: Hole in transfer case
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You would have to pull the front shaft and yoke to do that seal. If its dry leave it be. You can always do it later if it does go and it would have to be going for a while to be noticed. You pay more than enough attention to this so I would say let sleeping dogs lie. By the way, pure argon would work well on your case repair as shielding gas. Just not C25.
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MarineGrunt
Enthusiast
Sep 12, 2012, 11:19 AM
Post #11 of 35
(6144 views)
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Re: Hole in transfer case
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Thanks Nick.....are you saying I should just drop the back half of the t case rather than dropping the whole thing?
I kind of wish I would've just welded the housing instead of buying a new one. I guess I could still weld it and save it for a friend or anyone else who needs one repaired. I could just sell the new one too but since I have it I'm gonna use it.
My stepdad just ordered a wear plate for his 03 one ton. He's not taking any chances.
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
Sep 12, 2012, 11:55 AM
Post #12 of 35
(6142 views)
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Re: Hole in transfer case
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MG - If you can, weld the old one up OFF vehicle you could have it squeaky clean for use or sale with a better job no doubt. If perfect it would hold gasoline or something of real light viscosity. IDK - practice on that and know the other is new. Of course with my luck the welded one would be better
Tom
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nickwarner
Veteran
/ Moderator
Sep 12, 2012, 5:15 PM
Post #13 of 35
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Re: Hole in transfer case
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Might be easier to just pull the whole t-case, then you can get it cleaned up on a bench and ensure no grime gets into the case. Makes is easier to look over everything too, and when you go to mate the halves back together I like to have it standing up so gravity doesn't pull any of the shafts down and make it a pain. Its an easy enough thing to drop that case, and considering what you do for a living no doubt you can pull this without a jack. I'm not the biggest guy out there and I do it. Weld the inside and the outside, then sand down your beads inside to match the case. Obviously when you get it down you won't be able to see any porosity or cracking if done right. You know well what a good bead looks like, and its no different with aluminum. If you can get your hands on some 1/4" 6061 aluminum scraps that will help you get dialed in on your voltage. Bit easier learning curge with someone who is handy with TIG than it is using a spool gun on a MIG. I've fixed charged air coolers at work with a MIG and still after all my complaining can't get the boss to pony up the coin for a decent TIG.
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MarineGrunt
Enthusiast
Sep 13, 2012, 9:52 AM
Post #14 of 35
(6106 views)
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Re: Hole in transfer case
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I bet if you blew through some of those charges air coolers a few times the boss may just pony up. The key is to start costing him money due to lack of tools and equipment.  (I am kidding)
I'm pretty sure I can pull it without a jack. There's a reason I've had two back surgeries. I'm about due for a third anyways. Actually my back is better than ever and has been for about 3 years. With the case being aluminum doesn't seem like it'll be all that heavy. I'll probably just do it at home off of a jack so won't have to lower all that far to have it sitting on my chest. If anything I'll just chug a six pack so my gut sticks out a little further. Although I might have to sit there with it on my chest and blow ass a few times to lower theall case in order to be able to slide back out from under the truck.
I'm just gonna throw o and the new rear housing I purchased but I am going to try and weld up the old one. I think it'll be fun to try. I'll definitely have to practice on some scrap first because I have no idea what frequency to set it at. For steel tubes I usually run around 80 or so. When I take a tube test for my certification I usually run around 110 tho. It runs very hot that way and you have to move but you don't have to worry about not tying the two coupons together. The judges are anal and will nail you for the tiniest of anything. We just tig the root pass and fill and cap with 7018.
Hey Nick, are you anywhere near West Bend? There's a sticker on the back of the truck that says Bob Fish West Bend, WI. I'm pretty sure that's where the truck was originally purchased from.
Gonna pull the t case tomorrow evening. I wonder what other crap I'll run into cause that seems to be the way it goes for me!
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nickwarner
Veteran
/ Moderator
Sep 13, 2012, 3:29 PM
Post #15 of 35
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Re: Hole in transfer case
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West Bend is near Milwaukee area. I'm up in Eau Claire.
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MarineGrunt
Enthusiast
Sep 14, 2012, 7:48 AM
Post #16 of 35
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Re: Hole in transfer case
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I'm gonna start dropping the t case later on today. I have came across some info stating that many have had issues with the rear mainshaft bearing. Is this something that I should go ahead and replace? The new rear housing came with a front shaft bearing already installed. It also has a new output shaft bushing. I do have a new rear seal to put on. I don't think there's really anything else I need except the possibly the mainshaft bearing. I guess the original had a plastic housing bit the new bearing has a steel housing. Any thoughts?
Thanks
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MarineGrunt
Enthusiast
Sep 15, 2012, 5:54 PM
Post #17 of 35
(6046 views)
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Re: Hole in transfer case
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Transfer case is going good. Dropped and split it last night. Spent most the day taking my time cleaning it inside and out along with checking over everything. Planned on putting it back in but wife lined up a sitter for the kids and forced me to take her out to eat.
If it goes together as smooth as it came apart it shouldn't take any time at all to get it back in tomorrow.
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MarineGrunt
Enthusiast
Sep 16, 2012, 9:12 AM
Post #18 of 35
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Re: Hole in transfer case
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I could use some quick help here. I'm in the process of putting the case back together. I printed off some directions from the site where I purchased the wear plate. It says to make sure the spring is in place on the shift shaft. The problem is, there wasn't a spring there when I pulled it apart. It's possible it fell out but I looked around and didn't see it. Do all t cases have springs on the shift shaft? I have a 246 t case.
I figured it out. I came across some info and it says the shift detent and spring is no longer used. Whew! I doubt I would've been able to find one locally if I needed one. I would've had to wait til tomorrow. That would've sucked....I would've had to sit on my butt, watch football, drink beer and wait til tomorrow.
(This post was edited by MarineGrunt on Sep 16, 2012, 1:27 PM)
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MarineGrunt
Enthusiast
Sep 16, 2012, 7:44 PM
Post #19 of 35
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Re: Hole in transfer case
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I could use a quick tip. I took the shift motor off when pulling the t case so I wouldn't accidently damage it if I dropped the case. Now I can't seem to get the teeth lined back up. I didn't do anything to move them so not sure why it won't line back up. It's very close to where it needs to be. The bigger tooth is around 6:00 but needs to be at 5:00. I messed around with it for awhile earlier but was getting frustrated so decided to stop, hangout with the kiddos, and call it a day. Any suggestions?
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nickwarner
Veteran
/ Moderator
Sep 16, 2012, 8:27 PM
Post #20 of 35
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Re: Hole in transfer case
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Looks like you've been busy while I was out of town. Fun little bike rally in Tomahawk WI called Fall Ride. When you look at the motor and the gears it mates too, are any of the gear teeth marked with a small diple like a punch would make? They would be timing marks to get the teeth lined to each other. You may have to wiggle the input shaft a bit to slightly move it while puching it in to get it perfectly lined up. Or get a 10lb maul and show it how you REALLY feel. Its a pain in the ass because it pretty much has to line up dead on to go in properly.
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MarineGrunt
Enthusiast
Sep 17, 2012, 5:38 AM
Post #21 of 35
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Re: Hole in transfer case
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Sounds like you had more fun than me! The t case went good except for the shift motor. Wish I would've just left it alone. If I did I probably would've dropped the t case and broke it!
I don't recall any dimples but willI take a closer look. There is one tooth that is twice the size so iI can see where it's suppos to line up. It's close but not quite there. I wiggled everything and no luck. Is it possible to put it in place, have someone push 4hi or 4low, and push it on as the gear is moving? Seems like it would fall into place then.
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nickwarner
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/ Moderator
Sep 17, 2012, 2:50 PM
Post #22 of 35
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Re: Hole in transfer case
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Never tried that myself, but since it only goes in one way that might work.
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MarineGrunt
Enthusiast
Sep 18, 2012, 7:08 AM
Post #23 of 35
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Re: Hole in transfer case
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It ended up working. Nobody was around to help so I had to use a broom stick to push the 4lo button while holding the shift motor in place with my other hand. Everything is good except there seems to be a little bit, and I mean a little bit, of seepage out of the rear seal. I even used the $77 one from the dealer instead if the $34 one I also had on hand. I did fill it before installing the rear driveshaft so maybe it isn't seepage. I'm just gonna keep an eye on it for now.
Like always, thanks so much for the high quality advice! Looks like the Venture tranny is right around the corner.
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nickwarner
Veteran
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Sep 19, 2012, 3:51 AM
Post #24 of 35
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Re: Hole in transfer case
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You're probably on track about it not being seepage since you had the shaft out when you filled it. You finally get this together and now you want to work on the Venture again? You're a glutton for punishment. We are awaiting the next thread on the Venture and glad the truck worked out.
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MarineGrunt
Enthusiast
Sep 19, 2012, 7:43 AM
Post #25 of 35
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Re: Hole in transfer case
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Thanks Nick. Before I found this forum there were some jobs on my vehicles that I was nervous to tackle and would research for days and days before I'd jump into them. I guess you could say I was a little gun shy. Ever since I became a member of this forum I look over the Chilton manual for a few minutes, grab a wrench, and start tearing crap apart. It's a comforting feeling knowing you guys have my back. I know with your help I can tackle just about any job.
The Venture needs a tranny. I was gonna attempt a rebuild on it myself but I think I may just take it somewhere. I'll start a new thread when it's time for that one.
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