How to Rebuild a Transfer Case

If you are having problems with the four-wheel drive option on your vehicle, it could be a result of a faulty transfer case or one of its components. Fortunately, you can avoid the financial burden of a costly replacement by rebuilding your existing transfer case, rather than buying a new one. This simple guide will show you how.

Step 1 - Purchase Transfer Case Rebuild Kit

Visit a local auto parts store or shop online for a rebuild kit that is compatible with your make and model vehicle. Be careful with less expensive kits that claim to be rebuild kits, as they often only include seals and gaskets for the transfer case.

Step 2 - Raise and Secure the Vehicle

Use the heavy duty floor jack to raise the vehicle high enough so that you can slide the jack stands into place beneath the vehicle. Use 4 jack stands (2 in front, 2 in rear). Don't attempt to work on the transfer case with only two wheels supported.

Step 3 - Remove Skip Plate

Remove the bolts that hold the skip plate in place, and then set the plate aside.

Step 4 - Drain Transfer Case Fluid

Locate the fluid drain plug or bolt on the transfer case, and then place the plastic drip directly underneath it. Open the plug and allow the fluid from the transfer case to drain into the pan until it is empty.

Step 5 - Removing the Transfer Case

In order to remove the transfer case, you will need to remove several other components first. These usually include: the front drive shaft, shifter linkage, 4 wheel drive sensor, and the rear drive shaft. Once these components are removed, you can then remove the transfer case. Be sure to use the heavy duty floor jack because the transfer case is extremely heavy.

Step 6 - Open Transfer Case

In order to open the transfer case you will need to remove several bolts on the outer housing of the case. Once the housing cover for case is off, remove the retaining clip slide out the transfer case oiler from the shaft.

Step 7 - Remove Parts to Be Replaced

Remove the parts to be replaced inside the transfer case in the following order: snap ring, output shaft drive, chain, drive gear, front output drive gear, shifter shaft, input shaft seal retainer, input shaft snap ring, output flange, output shaft and input shaft (may be referred to as planetary shaft also).

Step 8 - Install New Parts

Install the parts from the kit in the reverse order as you did when removing them. Take care and lubricate components that need it.

Step 9 - Close Up Transfer Case

Reinsert the oiler disc, and then snap the retainer clip back into place. Carefully align the case housing halves and secure the two pieces with the bolts you removed earlier. Use a torque wrench to tighten the bolts to manufacturer suggested torque specifications.

Step 10 - Install Transfer Case

Place the transfer case back onto the floor jack and roll it under the vehicle. Then, have a couple of friends help you maneuver it back into the proper location. Bolt the case into place and secure it.

Step 11 - Fill with Fluid

Remove the fill plug cap or bolt and fill the transfer case with the appropriate amount of transmission fluid or specialty transfer case oil.

Step 12 - Install Other Components

Install the other parts and components you removed earlier.

Step 13 - Finish Up

Lower the vehicle and remove the jack stands.