Rebuilt Transfer Case
When a transfer case starts to fail you can repair it, or replace it with a new or rebuilt unit. Here is how to tell, and what we can supply.
What a transfer case does
The transfer case takes power from the transmission and splits it between the front and rear axles through two separate drive shafts. It bolts to the back of the transmission, or sits in the driveline behind it, and on most truck units it also carries a high and a low range. When it fails the truck can lose front drive, low range or both.
Signs of a failing transfer case
Strange noises
A noise like a gear popping out can mean the case needs lubrication or that a component is worn. It can also mean worn or damaged gears, or a damaged chain in a chain driven transfer case.
Gears popping out
If the case keeps jumping out of gear, the gears or the sliding clutch are usually worn and can no longer hold two or four wheel drive. It tends to come on gradually, but it points to a serious problem inside.
Leaking seals
Seals break down with time and start to leak. A leak left alone leads to low oil, poor lubrication and serious internal damage.
Hard shifting
Hard shifting can come from a bent or worn shift linkage, and sometimes the linkage only needs lubrication. If the linkage is fine, look for bent or damaged shift forks inside the case.
Shudder under load
A hard jerking motion while accelerating can come from the oil level, loose transfer case fasteners, worn gears or bearings, or a defective internal clutch. A shudder at low speed can also point to a defective viscous coupling or clutch pack.
Diagnosis: part time drive
| Noisy operation | Worn bearings, splines, chipped gears or worn shafts: rebuild the unit. Low oil: fill to the correct level. Loose or broken mounts: tighten or replace them. Gear driven cases always make some gear whine, which is normal. |
|---|---|
| Jumps out of two wheel drive | A weak or broken shift lever detent spring: replace the spring. A worn or tapered sliding clutch engaging surface: replace the worn parts. |
| Jumps out of gear in four wheel drive | Shift lever hitting the floor pan: provide clearance. Excessive case movement: check or replace the mounts. A tapered sliding clutch, a bent shift fork, a weak shift rod detent spring or torsion spring, or worn bearings, gear teeth or shafts: replace those parts or overhaul the unit. |
Diagnosis: full time drive
| Noisy operation | Low or wrong oil: fill to the correct level. Running in lockout on dry pavement: shift out of lockout. Wear on gears, chains or the differential: rebuild as needed. Loose or worn mounts: tighten or replace them. |
|---|---|
| Jumps out of, or hard to shift out of, low range | Shift linkage out of adjustment, bent or broken: adjust, straighten or replace it. Dry or scored shift rails: clean, polish and lubricate. Worn reduction unit parts: repair or replace. |
| Lockout will not engage | Damaged lockout parts, a defective vacuum control, loose or damaged vacuum lines, or a defective shift linkage: repair or replace. |
| Two or four wheel drive will not engage | No vacuum or loose hoses, a defective axle or transfer case shift motor, or binding shift linkage: replace the hose, the motor or the linkage, or repair the transfer case. |
| Vehicle drifts driving straight | Mismatched tire sizes or uneven tire pressure: fit a matched set and set the pressure. |
Rebuilt transfer cases by make
Rebuilt Fabco transfer cases
Fabco units rebuilt in our Orlando shop, sold outright or on exchange.
View detailsRebuilt Mack transfer cases
Rebuilt TC15 and TC25 units, and how to read the model code stamping.
View detailsRebuilt Oshkosh transfer cases
Rebuilt and remanufactured Oshkosh units, outright or on exchange.
View detailsRebuilt Rockwell transfer cases
Rebuilt Rockwell T-136 to T-228 units and the gears and kits for them.
View detailsRebuilt Spicer transfer cases
Rebuilt Spicer and Dana units, kits and Spicer manuals.
View detailsTransfer case parts
Kits, gears, yokes, shafts and housings for every major make.
View detailsWe also supply and rebuild ZF, BorgWarner, Marmon-Herrington, FWD and other units. Call (877) 776-4600 or 407-872-1901 with the model from the tag, or browse transfer cases on our online store. For exploded views and parts lists, see the transfer case manuals.
Have the tag in front of you?
Give us the make and model from the transfer case tag, and the serial number if you can read it. We will match the unit or the part, price it and tell you when it can ship.