263XHD Rebuild

[bml2200]

On my way back from SDX I realized that my transfer case was running empty. It started making a clicking noise and thats when I added more fluid to it. Around 70mph it also started vibrating and the abs and park brake lights came while the speedometer started moving around. I read that a bad bearing causes this. Looks like the rear output seal was leaking, not pump rub that caused this. The last time I moved the truck, it seemed to rev up a lot before it shifted to second and then slammed really hard into gear. Now I have a few questions:

1. Anyone have instructions for disassembly and reassembly for the transfer case?
2. Best place to get replacement parts? Merchant seems to have everything I could need.

 

[jlawles2]

try this site. http://www.makcotransmissionparts.com/NP261.html or this one http://www.merchant-automotive.com/tech/tcpv2.pdf


to split the halves, you need to spread the snap ring under the rubber plug on the top back. Other than that, its pretty simple just remove all of the bolts. NP installed a couple of pry points to help split the case.

 

[onebaddmaxxx]

Your snap ring grove can also be wore out. Mine was so bad I couldn't spread the snap ring to let the case slide off the main shaft and release the back half. Had to cut a piece off and allow me to get more access to snap ring. I put a alum rear case on mine