To Rebuild or Not to Rebuild

[6]

Someone, I'm not naming names, but someone I'm married to, tried to engage 4x4 with probably a 40mph difference in front to rear wheel speed.

That was the end of that.

This transfer case is very hard to find. It was only in the 2500hd, only 02-05, only in the push button engagement trucks. A 263-hd transfer case.

Looked for a while. I finally found one. It's in a truck in a salvage yard about 45 min from me and it's in a truck they have not processed yet. Hopefully in the next few weeks the truck will hit the yard and they will pull it.

I had to lie and pretend I didn't jump into the non-processed truck area and crawl under it to look.



I bought a rebuild kit.

I can toss the new one in the truck, rebuild mine and keep as a spare or sell as rebuilt. Or o can wait another month or so after getting the new one to send it out and have it rebuilt and install the new one rebuilt.

What would you do?

[squirrelman]

"never let a girl drive your truck" unless you're too drunk is good advice.

[6]

"never let a girl drive your truck" unless you're too drunk is good advice.

For a while she wasn't the best driver in anything big. Especially my truck..

Now you would be surprised... Had to have her bring it to me WAY out back the other day and she made it..

Lots of people I know, guys and girls, wouldn't have made it out there in it.

[rpcraft]

Someone, I'm not naming names, but someone I'm married to, tried to engage 4x4 with probably a 40mph difference in front to rear wheel speed.

That was the end of that.

This transfer case is very hard to find. It was only in the 2500hd, only 02-05, only in the push button engagement trucks. A 263-hd transfer case.

Looked for a while. I finally found one. It's in a truck in a salvage yard about 45 min from me and it's in a truck they have not processed yet. Hopefully in the next few weeks the truck will hit the yard and they will pull it.

I had to lie and pretend I didn't jump into the non-processed truck area and crawl under it to look.



I bought a rebuild kit.

I can toss the new one in the truck, rebuild mine and keep as a spare or sell as rebuilt. Or o can wait another month or so after getting the new one to send it out and have it rebuilt and install the new one rebuilt.

What would you do?

6 I think the problem with rebuilding the old unit is that you are going to need hard parts and that might not be economical for a rebuild, not just the parts for a typical rebuild. If the truck is still moving that is a decent sign but what probably gave way is the stuff connected to the front driveshaft (inside the case) and while it's possible the chain just broke it's doubtful, mostly because a lot of times when the chain breaks like that it shatters the case. I would say hold out for the replacement, depending on the miles it has on it, rebuild it if it is more than 150K or if somehow it has less I would just run it as is and check for any leaks and replace those seals. if it has decent fluid in it and you can drain it and not see a lot of gold in the drain pan it's probably in decent shape but the one thing you will want to check is on the back part of the case to make sure that the oil pump drive tabs are not cutting through the case. There is a case saver you can buy to install if it has wear there but otherwise they are pretty bullet proof units.

[The Cheese]

You can't make a well informed choice yet. You have no idea if the OG one is rebuild-able. Not until you take it apart. Might have broke something important inside. You also don't have the used junkyard case yet. You might not get it at all. Who knows when they will get around to doing it. Or if they are willing to hold for you. They might see how rare it is an hold onto it. Or auction it off. Way too many variables here.

Best to hold off until after you see if the OG is serviceable/rebuild-able. Then go from there.

[6]

You can't make a well informed choice yet. You have no idea if the OG one is rebuild-able. Not until you take it apart. Might have broke something important inside. You also don't have the used junkyard case yet. You might not get it at all. Who knows when they will get around to doing it. Or if they are willing to hold for you. They might see how rare it is an hold onto it. Or auction it off. Way too many variables here.

Best to hold off until after you see if the OG is serviceable/rebuild-able. Then go from there.

I already paid for the one in the truck at the junk yard. It's possible they will sell it out from under me still and credit my money back, but I'm hopeful.

And yes, the of case definitely broke something inside that is not in the rebuild kit. I'm just assuming that the transmission shop can get parts for it once they get it apart. Maybe they can't.

The truck is running and driving ATM. I like the idea of having a known good case in my hand before I turn a wrench. That truck is my only transport.

I don't like the idea that it can take them up to 45 days to process that truck, then another couple to pull the new case, and then I send it out to the shop and wait for the rebuild.

Not having 4x4 effects me daily as is. Almost got stuck in a field Saturday night, last week I had to pull my truck out of out dumping area out back in the woods with the tractor twice.... But the real ticking time bomb is the snow. I need that plow on (which puts all the weight forward and tunes it into a burnout vehicle) and the truck ready to plow before snow hits.

November? December? October? Who knows.

[rpcraft]

6, once you get the old one apart you will realize how easy they are to rebuild. The only thing you really need to get it apart is a set of snap ring pliers to get the rear retention snap out. There is a guy on youtube called Precision transmission that does some great tear downs and explanations. Not sure if he has one for your specific unit but it might be worth a search.

[frinesi2]

I know you've done some research, but, are there alternate cases that are more common that will fit? Is this thing completely mechanical or is it commanded by buttons?

[Goshawk]

I have extensive resources for transfer case parts and repair. I run a modified 263HD in my converted 6.6L Duramax Yukon XL. I’ve rebuilt mine once already. Contact me directly for info.

-P.

[6]

I know you've done some research, but, are there alternate cases that are more common that will fit? Is this thing completely mechanical or is it commanded by buttons?

This is not only the only one that will fit without struggles and mods, but from what I have seen these are the ones guys are trying to swap in place of the others because apparently the best/toughest one..


And ya, it's button controlled.

[6]

Here it is, a little metal slice of heaven!

IMG_20211027_165348.jpg

This is the tag I have be scouring the junk yards and underneath every Chevy pickup in them looking for.

IMG_20211027_165352.jpg

Hell yeah.

[frinesi2]

Noice. I'm equally excited to see the truck fixed as I am to see the innards of the toasted TC lol

[6]

Noice. I'm equally excited to see the truck fixed as I am to see the innards of the toasted TC lol

Hahaha.

Welp, I decided to install the case as is.

After a good cleaning us was very apparent that the case gas been recently rebuilt by someone who LOVES gasket maker and is VERY aggressive cleaning gasket surface with some form of grinder.

I don't want to invest in that new case. So it's in and the old one will be getting the rebuild then go in later.


The fucked up part, while under the truck we saw a small rust hole... Figured I would patch it.

Well it's bigger than it looked so I have the entire interior pulled out of the truck right now and a bunch of stamped sheet metal on the way. And a shift cable. And door pins.

Never ends, but I don't want to let it rot, so I'm best of just cutting the cancer out now and while I'm there....

[rpcraft]

So long as it's manageable then it's definitely worth it to fix it now! You might check into some of that fluid film based rust protection that is around. I know you North East guys have hell in the winter due to the road prep materials. I think you have to put it on once a season but definitely worth it if your rig is what you consider a keeper still. I think a gallon is about 50 bucks and I have seen some of the cheaper undercoating sprayer guns for about 40 here and there.

[6]

To continue from the transfer case project... Of course they sent the wrong metal for the floor.... So I cut out my floor and built a new one out if 16 guage plate.

I'm waiting on the mounts for the moldings now...

And I replaced the trans shift cable while I'm in there.

How these things snowball. Now I feel if I don't do the other side it won't have be symmetrical...

IMG_20211105_151907.jpg
IMG_20211106_100733.jpg


These things happen
....

By the time I'm done with this truck it will be 90% made in the shop..