how to tell if a transfer case is good

[cj8990]

gonna be buying a transfer case to use in my awd conversion and just wanted to know anything i should check to tell if its good... i know you have to check the input and output shaft play like on a turbo and to check if the splines are jagged but anything else i should check?.. also how difficult is it to open up the t case and check it out?... also a side question how many splines on the transfer cases from 95 X's? i will be using a 95 awd trans and wanna get the right spline count on the case

thanks in advance

 

[GRAVEDIGGER]

If you can rotate the input shaft and the output shaft turns freely that's as good as anything as far as checking it out. (quickly and easily)

You can use any 91-96 transfer case as they are all 23 spline and the correct gearing.

A 97-99 transfer case will have a 23 spline shaft, but it will have different
gearing inside.

 

[twicks69]

Bring a can of brake clean and some rags. Thoroughly inspect the input sleeve splines for squareness. If they are worn down or not square-shaped anymore, it is an expensive part to replace (~$300.00). If the output splines are worn or twisted, it would require a new ring and pinion gearset, again, another expensive part to replace (~$450).

If possible, take a 23-spline output shaft with you to aide in the turning of the transfer case to get a feel for the bearing condition.

The input and output seals are cheap to replace.

1990 22-spline transfer cases are not a viable solution and they can be identified by a couple things such as counting the splines on the input sleeve for 22 or 23 splines, as well as easily identifying them by the complete cast aluminum transfer case whereas the 1991-1999 cases have a cast iron front section and a cast aluminum tailshaft housing.

Hope these details help!

 

[JusMX141]

Pretty much as long as it turns freely (a little drag is OK) and doesn't have evidence of a huge oil leak you'll be fine. Stay away from those which do not turn and those which have oil and road grime caked to the exterior.

 

[cj8990]

so if im using a 95 trans for my conversion on my 97 will i not be able to use a 97-99 transfer case because of the different gear ratios?


thanks guys this really helps me a lot

 

[GRAVEDIGGER]

so if im using a 95 trans for my conversion on my 97 will i not be able to use a 97-99 transfer case because of the different gear ratios?

Correct

 

[cj8990]

why is that?.. just curious... i thought 95-99 awd trans were the same

 

[GRAVEDIGGER]

Here you go.

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[cj8990]

alright i got it now cleared everything up for me.. thanks for the help