Looking for help - Tcase Blew Up

[WatchDawg]

All,

Thanks so much for all the help with my m1009 since I got it, the experts on this form, are awesome.

So, I had an issue other day, long story short, the tcase blew up after driving for awhile, guessing it's been an on-going problem, that finally ended itself.

SO when the tcase blew, it also blew the speedo cable, tcase and some other parts on on the way, mechanic told me today that I needed a speedo assembly, according to the 1198 T.O., fig 291, I need the parts below.

My question(s) are... has anyone done this? areparts below all I need, or is there anything else I should look for?

PAOZZ 11862 9780470 GEAR SHAFT,HELICAL 1


UOC:194,208,210,230


4 XDOZZ 11862 3866918 GEAR,SPUR 1


UOC:231,252,254,256


5 PAOZZ 11862 15562374 SEAL 1


6 PAOZZ 11862 326561 SLEEVE 1


UOC:213,252,254,256


6 PAOZZ 11862 1362293 SLEEVE AND SEAL ASS 1


UOC:194,208,209,210,230


7 PAOZZ 11862 1254856 RETAINER,SPEEDOMETE 1


8 PAOZZ 11862 368026 ADAPTER,SPEEDOMETER 1


UOC:209


9 PAOZZ 11862 14018671 RUBBER ROUND SECTIO 1


10 PAOZZ 11862 8639743 SCREW,CAP,HEXAGON H 1


UOC:194,208,209,210,230,231,252,254


11 PAOZZ 11862 378362 CLIP,CABLE,SPEEDOME 1


12 PAOZZ 11862 11506101 NUT 1


13 PAOZZ 11862 474579 GROMMET,NONMENTALLIC 1

 

[porkysplace]

I would start with a complete used transfer case . It also looks like you need a new driveshaft or at least a new tube . The bend in that one would make a GL fork truck driver proud.

 

[swbradley1]

Wow! When you destroy a t-case you really go all in.

 

[Tinstar]

Wow!

You meant literally
Not just a figure of speech

Plenty of tcases out there
Get a new used one. I would check it out of course before installing.
New speedo parts
New DS tube

Back on the road

 

[PJL]

WOW! So just how did that fail like that? Glad no one got hurt from loss of control from parts removing themselves. I heard of a rocket crash described as a RUD event. Rapid Unscheduled Disassembly.

 

[corelokt]

I've torn up two np208s, but I've never grenades one. One came apart at 70 on a dry highway, my bad. One was just to much torque in a.hole.
I'm going to an np205 next.

 

[doghead]

Possibly caused by previous forklift damage?


Sent from my iPhone using Tapatalk

 

[pigpen60]

Bad part of the np205 is the low range is 1.96. Np208 is 2.69 isnt it?

 

[WatchDawg]

WOW! So just how did that fail like that? Glad no one got hurt from loss of control from parts removing themselves. I heard of a rocket crash described as a RUD event. Rapid Unscheduled Disassembly.

Basically i never drive it far normally, I took a friend to NJ and turned around for home... I think this has been a long term problem... but what we think happened is a small hole in tcase, fluid only drained when driving (not parked, so was hard to spot), after it ran out, and overheated, blew up.

 

[WatchDawg]

I would start with a complete used transfer case . It also looks like you need a new driveshaft or at least a new tube . The bend in that one would make a GL fork truck driver proud.

Got a good tcase on the way, Just need the info for the speedo cable, can't find it online,

 

[wheelspinner]

I have a complete used one here in NC. Its free if you want it, but I won't have time until later next week to peel it off the tranny, unless you can come to central NC. It came out of a good running 1009

EDIT: Saw the previous post after I wrote this one. Good Luck !

 

[cucvrus]

I have seen this before. The front driveshaft has a CV joint and if it drys out and the CV joint can not flex to will lock the CV joint and not be able to bend and it will push back on the transfer case and you see the results. You need the special grease fitting for your grease gun to grease this joint. It is outlined in a few lube orders I have seen. I know that a moderator from South America posted pictures of the grease fitting and the spot on the driveshaft CV joint inlet hole that needs lubed. I wish you luck. Pm me if you get in need of parts. I am not far away. Good Luck.

 

[porkysplace]

I have seen this before. The front driveshaft has a CV joint and if it drys out and the CV joint can not flex to will lock the CV joint and not be able to bend and it will push back on the transfer case and you see the results. You need the special grease fitting for your grease gun to grease this joint. It is outlined in a few lube orders I have seen. I know that a moderator from South America posted pictures of the grease fitting and the spot on the driveshaft CV joint inlet hole that needs lubed. I wish you luck. Pm me if you get in need of parts. I am not far away. Good Luck.

One of these.
https://www.walmart.com/ip/Lumax-LX...54589&wl11=online&wl12=47906887&wl13=&veh=sem

 

[Chaski]

View attachment 644878View attachment 644877View attachment 644876
All,

Thanks so much for all the help with my m1009 since I got it, the experts on this form, are awesome.

So, I had an issue other day, long story short, the tcase blew up after driving for awhile, guessing it's been an on-going problem, that finally ended itself.

SO when the tcase blew, it also blew the speedo cable, tcase and some other parts on on the way, mechanic told me today that I needed a speedo assembly, according to the 1198 T.O., fig 291, I need the parts below.

My question(s) are... has anyone done this? areparts below all I need, or is there anything else I should look for?

PAOZZ 11862 9780470 GEAR SHAFT,HELICAL 1


UOC:194,208,210,230


4 XDOZZ 11862 3866918 GEAR,SPUR 1


UOC:231,252,254,256


5 PAOZZ 11862 15562374 SEAL 1


6 PAOZZ 11862 326561 SLEEVE 1


UOC:213,252,254,256


6 PAOZZ 11862 1362293 SLEEVE AND SEAL ASS 1


UOC:194,208,209,210,230


7 PAOZZ 11862 1254856 RETAINER,SPEEDOMETE 1


8 PAOZZ 11862 368026 ADAPTER,SPEEDOMETER 1


UOC:209


9 PAOZZ 11862 14018671 RUBBER ROUND SECTIO 1


10 PAOZZ 11862 8639743 SCREW,CAP,HEXAGON H 1


UOC:194,208,209,210,230,231,252,254


11 PAOZZ 11862 378362 CLIP,CABLE,SPEEDOME 1


12 PAOZZ 11862 11506101 NUT 1


13 PAOZZ 11862 474579 GROMMET,NONMENTALLIC 1

Impressive!

I'd do what everyone else has suggested and source a used NP208C. You can find them in just about any square box Chevy from the 1980's that is sitting in a wrecking yard, or on Craigslist. I have bought a few for under $100. They are all identical in the Chevy applications except for the input spline count. I "think" the TH350 and 700R4 version has a 27 spline input, and the TH400 has a 32 spline input. If the input in your case is still good you could swap it into whatever you purchase if you cant find one with the correct input. They are pretty easy and inexpensive to rebuild. There is a place in Redding CA called Transparts Warehouse that I have had good luck with. They sell on eBay under a diffrent username.

The rebuild involves no special tools (torque wrench), about the only tricky thing is dealing with the loose roller bearings. You have to pack them with automatic transmission assembly goop to hold them in place.

 

[Recovry4x4]

If you do your fair checking at online auction sites, I'm sure you would find a new speedo cable for sale. Excellent grenade job by the way.

 

[WatchDawg]

Well Tcase is in, after getting it on a lift, now need speedo cable,

the pan was dented beyond repair, so will need one of those, and some gear linkage that blew apart as well.

Hoping i get it in shape for trip to GA in 2 weeks lol

Going to do a road test to see if the 2wd works as expected prior to putting in all together again, and testing the 4wd.