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Old February 10th, 2013, 11:07 AM   #1
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Angry Rebuilding a NP263XHD Transfer Case

Well it finally happened. The transfer case in my hauler (2003 Chevy CCSB 2500HD) stopped shifting into 4wd, lots of grinding and popping noise even though the indicator says it shifted. Long story short, found the hole in the back half of the case, the pump has worn a hole in the case and all the fluid is gone. No telling how long, and I suspect there is serious damage to the shift forks (at least).

I found a basic seal and rebuild package along with a pump upgrade kit from Merchant Automotive, but I am wondering if anyone has had any experience with this case? I dont have a problem with tearing into the case, but I really wont know the extent of damage besides the obvious things (broken or missing shift forks, bad bearings etc.) but what about damage to the planetary gears or other internals? Any ideas on how to determine what parts are out of spec?

A fully rebuilt case with the pump upgrade kit is $1600. Just looking at the prices of the rebuild kit, along with the high prices for the misc internals I wonder if it is even worth it to rebuild it? Its a lot of money in parts and I am not sure if it will be 100% when completed vs $1600 and a 2 year warranty.

What say you?
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