I'm only re-using the front output assembly at this point, but I will definitely make sure to check and flush that. The pictures in the album show a little bit of shininess on a gear inside the main assembly.

Eventually I'll probably try to rebuild the junkyard case, probably some time this winter.

 

Okay, I got everything put back together. Now the only issue I seem to be having is getting high range to engage. I don't have a problem getting low range to engage, but when I pull the lever back to put it in high, it won't engage and the warning keeps going off.

Any help here would be much appreciated.

Thanks.

 

You did drain the fluids, right?

 

It's been empty for a couple months, it was the original transfer case to the car that was pulled out by the shop. I did refill it though.

I'm thinking I need to adjust the cable. With the gear all the way forward and the cotter pin pulled from the lever the cable is much farther back on the t-case than the lever is, so this is probably part of my problem at least. Do you know what size crows foot I need to loosen that cable up?

Or something screwy with the electrical connectors on the t-case.

 

Ok, so it engages high range just fine, but I guess the computer doesn't recognize that so it just beeps at me incessantly. The batter is completely dead (I keep having to jump it), do I need to somehow reset the computer or something?