263xhd transfer case issues

Duc

Well-known member
Joined
May 30, 2020
Member Number
1679
Messages
712
Loc
ABQ NM
Vehicle: 2003 LB7 Duramax
Electric button transfer case
Pump rub kit installed about 8 years ago but didnt use 4wd afterwards.

The truck runs fine while in 2wd drive but runs into a issue after switching into 4wd. The truck will function and sound fine for 10-40ft till there is a small shock load on the system then there is a grinding sound with some popping noises. At a certain point I will just hear a zipper type noise with no movement. No issues shifting back into 2wd.

Hopefully tomorrow or Friday I can pull the unit from the truck. Search is pointing to bent shift fork, shift fork pads worn or stretched chain (long shot).

Any other suggestions?
 
Duc said:
Any other suggestions?
Click to expand...

Isn't there a computer relearn procedure for the push button cases if the shift motor is removed? Was it done after the pump rub install?
 
tac1 said:
Isn't there a computer relearn procedure for the push button cases if the shift motor is removed? Was it done after the pump rub install?
Click to expand...

The shift motor was aligned after the pump rub install kit. Transfer case goes into 4wd drive but pops out after abit.
 
Does it do the same thing low range and high? I'd look in the mode slider area, the c-clip behind it not being seated will cause limited engagement and popping out issues. It has been about 10 years since I have worked on one, so I didn't see many with fork wear issues.

Poor diagram showing the mode slide and snap rings from merchant-automotive site
mode slider.jpg
 
tac1 said:
Does it do the same thing low range and high? I'd look in the mode slider area, the c-clip behind it not being seated will cause limited engagement and popping out issues. It has been about 10 years since I have worked on one, so I didn't see many with fork wear issues.

Poor diagram showing the mode slide and snap rings from merchant-automotive site
mode slider.jpg
Click to expand...
I should have checked but I already had the case out by the time I saw your message.

Looks like some damage on the range hub
Range Hub.jpg


Some wear on the input gear attached to the planetary set
Input gear.jpg


Also looks like the large shift fork tapped the chain at some point.
Large shift fork.jpg


I wish alldata gave measurement to check for wear on items. Maybe I dont know where to look also. Output bearing snap ring area seems loose but that may be normal. This was a new front case about 8 years ago when I did the pump rub fix.
output bearing snapring.jpg
 
Duc said:
Looks like some damage on the range hub
Range Hub.jpg


Some wear on the input gear attached to the planetary set
Input gear.jpg
Click to expand...
A: While yes, there is face wear, that is not stripped and should not prevent engagment.


That is no concernable damage. Need to look at the plastics and the tips of the fork
Duc said:
Also looks like the large shift fork tapped the chain at some point.
Large shift fork.jpg


I wish alldata gave measurement to check for wear on items. Maybe I dont know where to look also. Output bearing snap ring area seems loose but that may be normal. This was a new front case about 8 years ago when I did the pump rub fix.
output bearing snapring.jpg
Click to expand...
The pocket is never a tight fit, the bearing has to free slip into the pocket for assembly.
 
So younger me was a ****ing idiot and it took a second to click. I was able to remove the planetary assembly with the input shaft from the case with no tools.

I forgot to install the snap ring on the input shaft. Im guessing this is my issue.
 
**** this dam truck.

Popped the front output gear out to replace the bearing and it decided to contact my phone screen. Nailed it just perfect that the screen is broken and not displaying. $100 for insurance claim on a S23+

Tomorrow I need to figure out how the company I ordered the seal and bearing kit is going to handle a miscommunication. I sent a email if I was ordering the correct parts but one of the part numbers was for a 261xhd and not a 263xhd. Otherwise Im out $250.



Truck 2, Phones 0
Phone 1 - Ran over when truck transmission popped out of gear during cable swap
Phone 2 - Tcase front output gear
:lmao:
 
It will only allow the input gear to slide inwards minisculely but it would explain the buzzing and some of the wear pattern on the inner teeth of the input.

Again, both forks look perfect.
 
total newb said:
It will only allow the input gear to slide inwards minisculely but it would explain the buzzing and some of the wear pattern on the inner teeth of the input.

Again, both forks look perfect.
Click to expand...

The snap ring was the issue in the end. The seal area for the input shaft has a polished section that was a extra 1/4 almost versus what it should have been. Truck tested fine in 4LO and 4HI for about 40 minutes on my large property. Before I would only get 10-40 till I had issues.


5 dollar snap ring ****ed me.
 
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