I have a Chevrolet Silverado HD 2003 3/4 ton 6.6 Diesel 4WD.

Question: The transfer case blew at 198K.   It had the common pin hole problem in the rear case caused by the oil pump rubbing on the case at 16oK.  Now its wearing out the range shift fork causing complete failure, it sounds like a binding when driving, It usually happens when it is under a load, hauling over 9K in 2 high or this last time in 4WD driving in about 15 inches of snow, but always under load can you help me?

Answer: Based on our re-manufacturing experience with the NP261XHD and from your description it sounds like an input shaft engagement teeth wear problem.  This resulting issue is premature fork wear.  The following is a list of parts recommended it you choose to repair the transfer case:

• Input Shaft 29 spline part number MWTNV43996 your cost $125.00.

• Seal Kit part number TRSTSK261XHD your cost is $55.75.

• Mode Fork Aluminum cast #28624 with pads part number MWTNV27756 your cost is $68.51.

• Range Fork Aluminum cast #17833 your cost $28.98.

This list assumes that you changed bearings at last tear down, if not order our part number MWTBK371A your cost $184.94.

A second option would be to replace the existing transfer case with a factory re-manufactured unit.  Order our part number TCGM041, this transfer case has a 12 month warranty, your cost is $1326.67 plus $350.00 core deposit plus freight.

If you need additional technical support, help with inspection, give Scott a call 888-824-2012 he can help you get the correct parts the first time.