I did a full transfer case tear down a year ago during my truck rebuild. Inspected everything and then reassembled with all new gaskets. About 6 months ago, I noticed one of my screwdriver bits missing from my toolbox... Figured it was gone forever, probably never to be found again.

Fast forward to this week, started noticing a single solid clunk on quick acceleration and deceleration. Did a little research and found recommendations for low t-case fluid and to just top it off. So i get under the truck this morning, remove the fill plug, stick my finger in to see how low it is, and I notice that it's only about 1/4-1/2 inch below the fill plug. However for being a year old it seems dirtier than I would expect.

So, I pull the drain plug and low and behold, it's my missing bit... FML. The bit has some damage so it obviously made some gear contact. Curious on what y'all think?

Pull the t-case and reinspect or should be fine, fill, and drive?

Either way, I figured my stupidity would be a good laugh for some! Enjoy!

 

That is a tough question. I guess I'd drain it, pull the inspection plate, and look for obvious and chronic damage first. If it looks ok I'd fill it and drive it a bit, but would have a very short fuse if I heard something I didn't like.

Bummer.

 

Fill and drive, see if the noise is still there. Oil looks kinda milky, do any water crossings?

 

drain, fill, and drive it like ya stole it !

 

I took the fill and drive route since the clutch didn't feel right on my backup car. Pedal was softer than usual and could probably use a good bleed.

Only a couple, but neither even touched the door sills. That milkiness is what tempted me to drain it in the first place. Still have the oil in the pan, I'm going to filter it tomorrow and see if it provides any insight.

I wish I had time before class to pull the inspection cover. I did make the 30 minute drive with the radio off and a focused ear on any noises. Thankfully none, including the hard acel and decel clunk. All felt normal. I need to replace the rear cover gaskets again anyways in the coming months, so I'll inspect it then.


Thanks both for the reassurance of my decision. Much appreciated

 

The bit didn't look too bad, whatever it snagged shot it out quick, like Walt mentioned I'd have a looksee at the gears to make sure no teeth are missing/chipped. Hell, it's an LT230, bulletproof transfer case if there ever was one, rivals the Dana 300.