98 Suburban 246 Transfer case clicking/popping

[Borguy]

@ MT-2500 : thank you for the link.
Like you suggested, it would have been a lot easier to remove the entire T-case instead of trying to split it still attached like I did last night !!

I managed to get the torsion bars and cross member out with a "modified" bearing puller
Splitting the T-case was something else
Finally got it out by sliding the chain off of the front driveshaft sprocket.

Now I could place the damn thing on my workbench and see/reach the bearing retaining ring from the little hole on top.
Notice : remove the two speed sensors or you won't be able to slide the shaft with bearing and all the rest out

Found exactly the same situation as ew0001, the originator of this thread.
All the bearing balls where sitting on the bottom of the bearing because a little corner of the plastic ring to hold them spreaded was broken off. This probably enabled that ball to push the plastic ring out of the bearing.

To reinstall I've put the shaft and chain back in on the part that was still attached under the car.
Then to get the backside cover back on you have to somehow hold the retaining ring of the new bearing open. For that I used a small piece of wood, exactly the same size as the little hole on top of the t-case. Pressed it in between the ring to hold it and once the cover was slided over and secured, I could retract the piece of wood and the retaining ring clicked in place

In the mean time it was past midnight and the rest will follow this evening....

[MT-2500]

Originally Posted by Borguy

@ MT-2500 : thank you for the link.
Like you suggested, it would have been a lot easier to remove the entire T-case instead of trying to split it still attached like I did last night !!

I managed to get the torsion bars and cross member out with a "modified" bearing puller
Splitting the T-case was something else
Finally got it out by sliding the chain off of the front driveshaft sprocket.

Now I could place the damn thing on my workbench and see/reach the bearing retaining ring from the little hole on top.
Notice : remove the two speed sensors or you won't be able to slide the shaft with bearing and all the rest out

Found exactly the same situation as ew0001, the originator of this thread.
All the bearing balls where sitting on the bottom of the bearing because a little corner of the plastic ring to hold them spreaded was broken off. This probably enabled that ball to push the plastic ring out of the bearing.

To reinstall I've put the shaft and chain back in on the part that was still attached under the car.
Then to get the backside cover back on you have to somehow hold the retaining ring of the new bearing open. For that I used a small piece of wood, exactly the same size as the little hole on top of the t-case. Pressed it in between the ring to hold it and once the cover was slided over and secured, I could retract the piece of wood and the retaining ring clicked in place

In the mean time it was past midnight and the rest will follow this evening....

You are welcome and thanks for posting back on how it is going.
Hope all goes well.
And let us know how it does.
MT

[Borguy]

Just finished the testdrive and so far all goes well

Once the T-case was back in yesterday, I kind of knew the rest would be easy. Just assembling everything (cross member, torsion bars, driveshaft...)


But while I was under it I noticed that the U-joint on the front driveshaft has a little slack. It doesn't produce any vibrations yet but that's probably the next project to work on

[Borguy]

Back in 2007 I replaced the rear tailshaft bearing.
Now, 45000 kms further on the road, same problem again

This time I found the plastic ball cage intact around the tailshaft.
Pushed the cage back in place and it looks like new.
But I already bought a new one (€120 !!) before I started the work...

The difference with this bearing is that the plastic ball cage is put in from the other side of the bearing. So it can't come out and "hang" around the tailshaft. It will sit against those "splines" where the sensors read.

Hopefully better luck this time ...

[HanibalTheCannibal]

FYI to all searching these forums on the 246 like me

there is an updated rear bearing that is sealed. You can get it at riverside gear. There is also a fix to the case wear problem (if your transfer case is leaking from a hole made by the oil pump).

oil pump hole fix:
http://www.riversidegear.com/categor...oduct-630.html

updated rear bearing:
http://www.riversidegear.com/categor...oduct-632.html

Bet your a$$ im getting these both when I rebuild mine soon!!

[Labpadre]

I have a '01 Suburban 3/4. Has AutoTrac II TC. The clutch burned up. Fluid was dark. Stealers replaced TC. 4 months later with approx 100 miles of 4x4 in the sand and a few miles on mountian terrian 4x4 does not pull in reverse and seems to not pull as much as it used to after the TC was replaced. Defective? I smell a slight odd burning odor. I'm about sick of this Autotrac Crap! Granted my Sub is Supercharged via Whipple. Do you think the whipple is eating the TC?