Wi | 69zfarmer - 3/6/2015 16:13 Pump rub club?
Transfer Case pump rub , common issue on every 261XHD/263XHD transfer case which you will find behind every 4x4 Duramax from 01-07 before the body style change. Many other cases can also have this issue as well. Simply put, there pump rides on the output shaft and the extension housing is used to hold it in place, the tabs are very thin and once the wear clip is worn through, falls off or breaks the tab will start to cut into the housing until it cuts all the way through it. At that point fluid starts leaking out, but it only really leaks when you a driving and not much at that. Eventually you end up with a dry case which is no bueno. An entire transfer case is $1,800. Used ones are $1,000. Just a rear housing is $300. If you already have a hole you can patch it with JB weld. You can try to weld it but it is magnesium alloy and finding people who have the right filler and will work with it are few and far between. A product like JB weld works great.
The best solution is something like Merchant auto's pump rub kit, its cheap and is very high quality and does the job. Install is simple, just a couple hours.
http://www.merchant-automotive.com/p-4017-transfer-case-pump-upgrade-kit.aspx
Here's some pictures
The tiny hole
What inside looks like (with pump rub, new there is a metal clip covering this and no wear)
All patched up.
Edited by durallymax 3/6/2015 18:09
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06 Silverado making noise when coming out of 4WD
