Hey Everyone---First Post. I have an '02 2500HD Ext Cab Short Box w/6.0L. I have about 113,000mi on it, and had it since mile one. I've been lucky avoiding wrecks, nicks, dings, etc(knock on wood) and, somehow avoided rust while living in Iowa. Still love the truck, looks great, drives great--and its nice finally having it paid off. So I want to keep it top notch, and get it to 200,000.

I'm starting to run into some of the higher mileage fixes. Over the last year, I had to replace the multi-function switch in the steering column as headlights quit working(!!$$$), replaced a door switch actuator, front right wheel bearings(pricey due to the anti-lock I found), few others. I guess all in all not too bad for the mileage.

However----it looks as though I will have a big expense coming up.
At about 60,000, I had a leak in the transfer case. I took it in and found that it was the front t-case seal. I was concerned as I heard about the problem with cracked t-case seals, but it turns out it was just a seal.

At about 90,000, I started hearing a clank when shifting into drive, or back and forth from Reverse to Drive. We finally tracked it down to the Transfer Case. The rear output shaft has a ton of slop. From what I have heard, it is just a bushing, not a bearing, and this wearing out is a fairly common problem. Not sure if the seal issue had anything to do with this.

My understanding is you have to pull the case out to even replace the bushing, and for the cost of pulling it, you might as well do an entire rebuild.

The rough estimates I have received are anywhere from around $1500 to rebuild, and about $2000 to just swap in a rebuilt one. I couldn't afford either fix at the time, so I have been just driving it hoping for the best for now. However, I think it is getting worse. The clank is about the same, but I think it is turning into a rumble/grinding on the highway.

My questions:
1) Do these estimates seem reasonable?
2) Is OEM rebuilt the way to go, or do we have any aftermarket, more heavy duty options?
3) Any opinions on whether I should rebuild, or swap with rebuilt?

I will be doing a lot of towing, and I don't do much 4 wheelin, just mainly when the snow hits.

Any suggestions or help would be appreciated.

Thanks

 

I would rebuild it....check with the dealer or a good tranny shop and see if there are any "updates" for your T case

 

my dad is a certified trans tech and were im from the rebuild/replace prices start at about 2400$,so i would say thats a fair price.they do have heavy dutie internal parts avalible for you trans case(towing and 4wheelin).