Putting an 04 CDL transfer case into my 03. I see posts about just switching the front output assembly. In posts regarding rebuilding a transfer case I see mention of tight clearances and the need to shim for proper fit. Is that not important when swapping just the front assembly? Anyone that has done it and had problems with excessive wear? Want to understand the cons.

I'll switch the whole transfer case but am all for easier if I get the same end result. I welcome your comments.

 

i was contemplating swapping just the output assembly but read several threads on here about how you're likely to run into different tolerances and wear patterns between the two separate sections, which will (supposedly) lead to early failure. so i'm swapping out the entire transfer case instead.

 

I’m coming to the same conclusion especially since no one is weighing in with success stories