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Old 04-19-2018, 03:12 PM   #7
87Skier
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Join Date: Mar 2014
Location: Corvallis, OR
Posts: 711
Re: Anyone rebuilt their transfer case?

Just did mine last year. I bought a complete rebuild kit off eBay for around $100 with a mix of Timken and Koyo bearings. Some of the new stuff comes with the rollers preloaded and retained so you don't need to pack all these in.

The largest roller bearings in the transfer case are unavoidable though. Have grease ready.

Replace the shifter shaft seals, and use some scotch brite pads to clean the shafts. I used high tack sealant on all the covers and seals and haven't had any leaks since.

It's pretty easy in terms of rebuilding stuff. If you've done wheel bearings and races before you can handle this. Geb Built's guide on YouTube is a good step by step video guide.
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1972 GMC Jimmy Custom 4.8L (L20)/6L90E/NP205
1989 Chevy Suburban V2500 350/Turbo 400/4.11 gears
1996 Chevy Suburban K1500 350/4L60E
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