Need Transfer Case help,, please

Just 1 More · 05-13-2008, 07:30 AM

Any transfer case experts on here??
I have a 2002 2500HD 4x4 6.0L (170,000 miles)
The transfer case was run in 4 high for a few miles at high speed.. this has been about 2 years ago. Since then I have had noises coming from it. I have drained and flushed the case several times and each time there is a lot of black, gritty fluid and I have to take a screwdriver to the drain hole to get fluid to come out. Each flush and drain does quiet it down.. but it is getting worse. The rear drive shaft has a lot of play (A LOT) at the tail shaft housing.
Does anyone know where to see an exploded view of the transfer case and a good place to get a replacement? Are these hard to rebuild myself? Yes, I'm pretty mechanicly inclined. Built engines and street rods for years, Do all my own mechanicing, but never a tranny or transfer case.
The numbers off the case tag are
MODEL: 263 HDGM
ASSY NO. 1257 6370
Serial NO: 06 17 02 G3
RATIO: 272

THANK YOU

stumpuller454 · 05-13-2008, 06:30 PM

best place to get a pic is from GM, and the best way to do it yourself is if you buy a GM service manual for your truck, but they are usually expensive and you have to wait to get them. is it an auto t-case? not too sure were all the black junk could come from unless its the syncro discs from and auto case or possibly the pump?. but if you think your rear shaft has excesive play your rear shaft bushing could be on the way out, never seen that before though, and your rear seal would prolby leak like a ******. i would check into prices for a rebuilt unit or a good used one, its rare that i replace many bearings, usually seals and chain, sometimes sprockets, it can be a bit ofa thing to tear down and repair, you`ll need big externall snap ring pliers that have flat tips instead of the common pin tips. IF you get a good tear-away pic of it should be do-able.

05-13-2008, 07:30 AM	#1
Just 1 More Junior Member Join Date: May 2008 Posts: 1	Need Transfer Case help,, please Any transfer case experts on here?? I have a 2002 2500HD 4x4 6.0L (170,000 miles) The transfer case was run in 4 high for a few miles at high speed.. this has been about 2 years ago. Since then I have had noises coming from it. I have drained and flushed the case several times and each time there is a lot of black, gritty fluid and I have to take a screwdriver to the drain hole to get fluid to come out. Each flush and drain does quiet it down.. but it is getting worse. The rear drive shaft has a lot of play (A LOT) at the tail shaft housing. Does anyone know where to see an exploded view of the transfer case and a good place to get a replacement? Are these hard to rebuild myself? Yes, I'm pretty mechanicly inclined. Built engines and street rods for years, Do all my own mechanicing, but never a tranny or transfer case. The numbers off the case tag are MODEL: 263 HDGM ASSY NO. 1257 6370 Serial NO: 06 17 02 G3 RATIO: 272 THANK YOU

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05-13-2008, 06:30 PM	#2
stumpuller454 Senior Member Join Date: Dec 2007 Location: Really FAR NORTH! Posts: 1,029	best place to get a pic is from GM, and the best way to do it yourself is if you buy a GM service manual for your truck, but they are usually expensive and you have to wait to get them. is it an auto t-case? not too sure were all the black junk could come from unless its the syncro discs from and auto case or possibly the pump?. but if you think your rear shaft has excesive play your rear shaft bushing could be on the way out, never seen that before though, and your rear seal would prolby leak like a ******. i would check into prices for a rebuilt unit or a good used one, its rare that i replace many bearings, usually seals and chain, sometimes sprockets, it can be a bit ofa thing to tear down and repair, you`ll need big externall snap ring pliers that have flat tips instead of the common pin tips. IF you get a good tear-away pic of it should be do-able.