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Old February 10th, 2013, 11:07 AM   #1
pipepro
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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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Old February 10th, 2013, 11:35 AM   #2
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I had a similar thing happen last year just onto the western slope of Colorado. None of the parts inside the case were salvageable after it grenaded. I'd open it up, make sure you still have good shift hubs and forks and case(Bearing Lands) or you'll be more than 1600 to repair. I ended up buying a re-man from LKQ for $1300, and it came with a 3 year warranty.
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Old February 10th, 2013, 02:14 PM   #3
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I think thats the plan so far. Pull it, open it up and see what kind of damage I can identify.
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Old February 11th, 2013, 01:09 AM   #4
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Lots of guys on the duramaxforum and dieselplace have rebuilt them, themselves. Its not a big deal. Pump and bearing are probably trashed, as well as the TC chain.
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Old February 11th, 2013, 12:02 PM   #5
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Google GM tranfer case "pump rub". It is a common problem with the HD trucks. Merchant Automotive has update kitto preventthis from hapening again.
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Old February 11th, 2013, 12:15 PM   #6
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I redid mine with the kennedy diesel plate

Some guys say you can just JB weld the case from the inside, or if you want there are several rear halves on ebay.
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Old February 11th, 2013, 12:29 PM   #7
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Quote:
Originally Posted by RADRICK View Post
Google GM tranfer case "pump rub". It is a common problem with the HD trucks. Merchant Automotive has update kitto preventthis from hapening again.
Yep, I mentioned Merchant in my OP, I know about the pump problem.

I am really more concerned with the amount of damage done to the gears and such and knowing if they are still within tolerance. I think that is my biggest problem, is deciding weather or not the internals are still good. I can easily diagnose the shift forks being bad, and excessive play in the chain, its the other machined parts and clearances that I dont know about. They are very expensive and the decision to start putting parts into it vs just getting one with a warranty is the question.

Its all pissing into the wind till I get it out and torn apart. I was just wondering if anyone had the same problem and what they discovered when they tore it down.
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