Transfer Case Repairs

A transfer case rebuild is when the unit that sends power from your transmission to your front and rear axles (in a 4WD or AWD vehicle) is completely disassembled, inspected, and reassembled with new internal parts

Why rebuild a transfer case?

• Symptoms of trouble: grinding noises, difficulty shifting into 4WD, slipping in and out of gear, fluid leaks, or metal shavings in the oil.
• Causes: worn bearings, damaged gears, stretched chains (in chain-driven cases), or bad seals.

What’s done in a rebuild?

1. Removal from vehicle – The transfer case is taken out for bench work.
2. Disassembly – All gears, bearings, shafts, and chains are pulled apart.
3. Inspection – Checking for wear, cracks, or pitting on gears and shafts.
4. Replacement parts installed:
• Bearings and races
• Seals and gaskets
• Chains (if stretched)
• Fork pads or synchronizer rings (in some cases)
• Any worn gears
5. Cleaning – All components and casing are cleaned to remove old fluid, metal debris, and sealant.
6. Reassembly – Everything is reinstalled with precise clearances and torque specs.
7. Refill with correct fluid – Usually ATF or specialty transfer case fluid.
8. Reinstallation and testing – Fitted back into the vehicle and tested in both 2WD and 4WD modes