So I've been putting off swapping out my transfer case on my 02 Tahoe 5.3 4x4 with the autotrac 2 for quite some time now and just kept filling it. Well i finally did it as of the last couple days. The old one had enough play to eat the hell out of the rear driveshaft yoke and i replaced it sometime last year along with the output seal.
The t-case I used as replacement is the same model number and everything according to the label plate. Replaced the input seal, new output and the felt gasket between it and the trans. I get the sob back up in there by hand and start plugging everything up and get to the last 2 plugs to find the tcase has a single connection on the motor as opposed to the old that has 2 as well as splines on the shaft whereas the old is rounded with 2 flat spots...
Google hasn't been my friend on this other than finding out gm switched motors on a 03 and forward and a bunch a dead ends on solutions other than getting another tcase meant for an 02. It'd be great if there was some sort of wiring adapter or someone knew the right orientation to splice that I could possibly do and it actually work.
I have taken my front drive shaft out and set the shaft in the tcase to 2hi and it is working fine other than the possibility of it jumping out of gear or in another. I left the motor off in case that happened while on the go and I need to switch it back to 2hi. It was a pain getting the motor lined back up and oriented with the gear the tcase was in after taking it apart to get the gears positioned right only to find tcase was in nuetral after finally getting it bolted back up. Which is why I left it off for now but i plan to take the motor apart again to line it up for 2hi in hopes it will better keep the tcase from switching gears. It is not leaking at all with the motor off and I have no leaks anywhere now.
I test drove it and it's running great and Trans even shifts alot smoother without all the extra drag from the old tcase.
Any advice or knowledge on a solution other than another tcase or rebuilding the shot old one for this would be greatly appreciated. I have come to terms with just not having 4x4 until I can afford another overhaul and hope for the best. Also if anyone has went the route I have and haven't had any issues just running as is would be helpful knowing so. It's not an option to get rid of the tahoe with as much time, labor and funds I've already put in it well before this. I learned it can take a distracted Kia Sorento traveling at about 50mph to the ass while i'm sitting still. Only a dent in one of the barn doors. The Kia was destroyed and started traveling in the opposite direction. My daughter who was about 6 months old at the time slept through it... It's taken me to many states and across the Mackinaw bridge and back through a Christmas blizzard while pulling a loaded trailer about 3yrs ago while having 280k miles without skipping a beat. I discovered the leak and clanking a few days after my return from that.
Thanks and sorry for all this to read..I'm pretty fed up and wasn't trying to be very grammatically correct here.
The t-case I used as replacement is the same model number and everything according to the label plate. Replaced the input seal, new output and the felt gasket between it and the trans. I get the sob back up in there by hand and start plugging everything up and get to the last 2 plugs to find the tcase has a single connection on the motor as opposed to the old that has 2 as well as splines on the shaft whereas the old is rounded with 2 flat spots...
Google hasn't been my friend on this other than finding out gm switched motors on a 03 and forward and a bunch a dead ends on solutions other than getting another tcase meant for an 02. It'd be great if there was some sort of wiring adapter or someone knew the right orientation to splice that I could possibly do and it actually work.
I have taken my front drive shaft out and set the shaft in the tcase to 2hi and it is working fine other than the possibility of it jumping out of gear or in another. I left the motor off in case that happened while on the go and I need to switch it back to 2hi. It was a pain getting the motor lined back up and oriented with the gear the tcase was in after taking it apart to get the gears positioned right only to find tcase was in nuetral after finally getting it bolted back up. Which is why I left it off for now but i plan to take the motor apart again to line it up for 2hi in hopes it will better keep the tcase from switching gears. It is not leaking at all with the motor off and I have no leaks anywhere now.
I test drove it and it's running great and Trans even shifts alot smoother without all the extra drag from the old tcase.
Any advice or knowledge on a solution other than another tcase or rebuilding the shot old one for this would be greatly appreciated. I have come to terms with just not having 4x4 until I can afford another overhaul and hope for the best. Also if anyone has went the route I have and haven't had any issues just running as is would be helpful knowing so. It's not an option to get rid of the tahoe with as much time, labor and funds I've already put in it well before this. I learned it can take a distracted Kia Sorento traveling at about 50mph to the ass while i'm sitting still. Only a dent in one of the barn doors. The Kia was destroyed and started traveling in the opposite direction. My daughter who was about 6 months old at the time slept through it... It's taken me to many states and across the Mackinaw bridge and back through a Christmas blizzard while pulling a loaded trailer about 3yrs ago while having 280k miles without skipping a beat. I discovered the leak and clanking a few days after my return from that.
Thanks and sorry for all this to read..I'm pretty fed up and wasn't trying to be very grammatically correct here.
