Transfer Case Rebuild - '04 1 ton Cummins

Hey guys,
Have any of you rebuilt your own transfer case? The case in my truck needs a rebuild, and I'm trying to decide whether to find a place, or do it myself. My case is a NP 271D.

Not hard to work on. What is wrong with yours?

Sorry- forgot to check back on this.

Mine won't stay in 4 wheel low - it jumps out on its own. I have checked the shift linkage, and it isnt an engagement problem. It also seems like the chain is stretched because in 4wheel high, under load, i have experienced what seems like skipping of teeth or the chain slipping.

My truck has 311,000 miles on it. previous owner rebuilt the trans, but i dont think they touched the transfer case at the same time. I only put a couple thousand miles on the truck each year at this point. I would like to get it working the way it is supposed to - as this is my tow vehicle.

Most common problem with popping out of low is the shifter. If the shifter pivot bushing is tight you may not be getting into the low range detent. I have fixed many by repairing the shifter and getting the adjustment dead on. If the chain is slipping you should notice it all the time on a hard pull. Again if the shifter is stiff you could be jumping in and out of 4wd.

Ok. Sounds like i need to spend more time troubleshooting it.

If you have an area you can drive it in low range do this. Pop the rod off the lever and make sure it is in low range. Then drive it. If it does not act up you know it was linkage. Then do the same in 4wd high. Again if it works ok it was linkage. If both tests still show issues you know that repairs are needed.

That makes sense. I live on 20 acres - so i can do that.

Thanks!

Hey man - you were right. The bushings and factory linkage were worn, and not adjusted properly. I had some rod ends and an aluminum sleeve laying around, and I made my own linkage. Now, I can get all the transfer case gears to engage, and stay engaged while driving around. Thanks for keeping me from pulling it out prematurely!

I do need to sink some $$$ into this old girl though. It needs brakes, and I think axle joints. It crab walks pretty bad even in 4H. Even in grass and on gravel.

It is a handy truck to have around when I need to use it!

Glad it worked out.

easy fixes are the best fixes !
i can just imagine me trying to heft around that transfer case. that thing would squash me like a bug !
glad it worked out for you.

I've had to replace the bushings in both ends of the 4WD shifter to transfer case linkage in my 2004 2500 Dodge diesel. I rarely use 4WD in my truck, so the bushings must just be junk. I like your idea on making your own linkage. Is that just aluminum tube and Heim joints? Looks slick!

Yes- just 3/8" heim joints and aluminum tube. I buy this stuff from McMaster Carr.