Re: non-pw transfer case problem


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Posted by Charlie on Friday, February 09, 2001 at 1:55AM :

In Reply to: non-pw transfer case problem posted by Mike in Belgium on Thursday, February 08, 2001 at 4:58AM :

I agree, it's probably the cahin. It may have already worn enough aluminum off to make the case worthless. I have a very low opinion of all the new aluminum transfer cases. This chain problem is common. Other common failure modes are:
1) Rock hitting case and breaking it because it's thin aluminum
2) Internal oil pump fails and the tiny planetary low range gears explode, destroying entire transfer case.
3) Bearings fail, impossible to access without removing and dismantling case.
The bolt pattern between your transmission and Tc is the "standard" evenly spaced circular 6 bolts. You have several superior replacement options:
1) Cheapest and strongest is NP205. Cast iron case, strong wide gears, easily accessible large bearings. The only problem is 1.96 low range instead of 2.7. GM version NP205s with the necessary 32 spline input shaft are abundant. If you are lucky enough to have the SM465 4spd with 6.54:1 1st gear you really don't have much need for a 2.7 low range as opposed to 1.96.
2) Equally strong with 3.94:1 low range is NP203/205 "Doubler", sold by www.offroaddesign.com The front 5.75" gear reduction box of the NP203 (cast iron, big gears, externally accessible bearings) is attached to a strong steel adapter and then to a NP205. This raises the cost by ~$1000. Overall length is comparable to the NP241 removed. Even with an automatic you will have an at least 40:1 low-low 1st ratio.
3) Sightly less strong but still adequate would be an Advance Adapter Atlas transfer case. It's built of thick aluminum but has big gears, big accessible bearings and choice of 3 low range ratios: 3.04, 3.77, 4.33. It costs roughly $2000.
You have a golden opportunity to get rid of a weak link in your drivetrain.
Charlie




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