Transfer case swap candidates for 96XLT

[jbeta]

Hello,

I have been having some occasional loud clunks and clicking noises in my drivetrain that I'm pretty sure now is the transfer case. The "clunk" noise is similar to what happpens sometimes when switching into 4-low, but louder. Here is what I found in the oil when I changed It:

Notice the glittery metallic layer that settled over night.

And later I found this:

Chunks of a non-steel (i.e. my magnet wont stick to it) metal about the size of a BB (I think the other thing is just a stray rock) there were lots of smaller chunks too I didn't photograph. Also, the fluid I recovered was about half of what should have been in there.

So would you guys say that I'm probably on the right track with the transfer case? I'm going with that assumption and heading to the junkyard tomorrow that has a few 95 and 96's. I am pretty sure I am looking for a BW44-05.

My question is whether a 4405 from a 97+ will bolt on, considering for example that the front U-joint was replaced with a CV joint after that. also, I have 2WD, A4WD, and 4WD-low, and I know the 97+ have different modes (no 2WD), but does the case care about that, or is it just the electronics?

I have gathered most of the information I need for this already, but I'm not sure about 97+ so If I can't find a good one on a 95-96 I'm not sure what I'll do.

Also, I might go ahead and order a rebuild kit for the new case, and do that before installing since there's a good writeup on here. I'm not afraid of that process except I'll have to get a blind puller for one bearing. I can still drive the truck if necessary for the moment, but I'm trying to avoid it as much as possible.

Any advice would be appreciated!

 

[Flash]

Some time in '98 the speedo drive went from the transfer case to the diff housing.

 

[jbeta]

Some time in '98 the speedo drive went from the transfer case to the diff housing.

Oh yes, thank you I forgot about that! So I will watch for the speed sensor.

I'm still wondering about the input and output shafts on the 97 though. I thought I read somewhere there was a different number of splines on the transmission at some point. I don't want to drop my TC yet though, so I'm thinking I'll just compare the vehicles they have on the lot. Hopefully they haven't all been harvested already. (I just checked and they got 2 more 96's just yesterday!)

 

[shadowless127]

Oh yes, thank you I forgot about that! So I will watch for the speed sensor.

I'm still wondering about the input and output shafts on the 97 though. I thought I read somewhere there was a different number of splines on the transmission at some point. I don't want to drop my TC yet though, so I'm thinking I'll just compare the vehicles they have on the lot. Hopefully they haven't all been harvested already. (I just checked and they got 2 more 96's just yesterday!)

97+ V6's use a 5spd auto not the 4spd you have.

 

[Flash]

Oh yes, thank you I forgot about that! So I will watch for the speed sensor.

I got caught like that.

The back plate near the output flange is interchangeable so you can convert a '98 to a '97.

 

[jbeta]

Thanks. I found a 96 today with what appears to be a well maintained TC. The fluid was fresh and the truck looked like it had been maintained except for cosmetic wear.

I did notice a splice in the "brown wire" that makes me curious if it was modified at some point, but I don't think that is necessarily bad unless they abused it.

So now I just need to install it. I think I'll wait on the rebuild kit for the moment. I might disassemble the old one first to look at its condition and as practice.

 

[jbeta]

Yep, it was the transfer case. Specifically the oil pump. Take a look:

I believe what happened is the retention tab broke and started spinning sometimes (the occasional thump thump thump was possibly the tube spinning around.)

EDIT: The real question is why the tab broke. The oil pump seems stuck rotating with the output shaft. I assume it rides on a bearing that went bad?

So I'm not sure what else might be affected, but everything else looks fine (once the shredded metal is removed.) It's a shame because I don't really want to spend money fixing it but don't really want to throw it away either. I'll probably clean it up and hold onto it in case the junkyard part craps out.