Need Advice Re: 1999 1500 Sub 4x4 Transfer Case Situation

Johndavidrichards

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Hello guys,

Would appreciate your advise on my 1999 Suburban and the situation I am currently in. First of all I just love this truck. I have several other newer vehicles and I keep grabbing the keys to this old truck to drive it instead.

Everything on the truck works and the engine is strong and makes no noise.

Ok so I started to get a grinding noise from the transfer case. Much easier to hear at slow speed or as you are approaching a stop sign. I also noticed some poping noises in parking lots. Needed a new case or I could drive with it like that until it failed I guess.

Just for reference at this point the Transfer case is the push button type with 2WD/AWD/4WDH/4WDL Model 243C 272 Ratio New Process Code NP8

So being the thrifty guy that I am, I became aquainted with a young man that does repairs on the side. Works at a shop during working hours and he offered to rebuild the case for me. I jumped at the opportunity.

Parts wise he replaced the bearings,chain, shaft and seals. After reinstall we determined that the shift motor needed to be replaced too. All told I am into this for about $500 at this point including the shift motor. During the install he screwed up the front drive shaft and had to buy a used one.

So he provided me with the truck to drive while getting the new front drive shaft. I drove it in 2WD all week on and off.

Yesterday he came to my house and installed the front drive shaft and we went for a test drive. Worked fine in 2WD then we stopped at a parking lot about a mile away to test the 4WD. I put it in AWD and drive about 100 years all ok. I then shifted into 4WDH from nuetral and put it into drive. Drove about 50 feet then a horrible snap crunch and pop noise errupts from under the car then a dragging noise.

Put the car in park and looked under to inspect. Front drive shaft is snapped off at the front Diff. parts everywhere. Leaking fluid from a crack in the case.

If there was ever a time that I wanted to put my foot up someones butt then this was the time.

We collected all the parts and I put the truck in 2WD and limped the mile home leaking AutoTrak the entire way.

Here are my question:

1. Rebuilt or Used Replacement Transfer case?

2. What do you think caused this failure. Just a bad rebuild and a cat failure or could there be something else like some sort of jacked up problem with the AWD and speed sensors.

3. If was told by someone that these vintages of AWD systems required you to replace the tires 4 at a time or the system would get tricked into thinking the wheels where spinning and your would wear out your case. You know the front tires are a bit smaller due to wear then the rear that may be newer.

4. I'm leaning toward just buying a reputible rebuilt one with a warranty so that I can feel confident that it won't leave me stranded. What should I look for in a good rebuild and what do you think is a fair price?

Thanks in advance for your insight in this matter.

JohnR
 
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