repairing 800 series transfer case

[jason@snakeriver]

With my limited experience, I assume that the most common problem with an 800 series transfer case is the in ability to get into high gear.
I am told that there is a fork and a syncro that go bad.
BOYCE says that they want $2500.00 exchange for a rebuilt transfer.
Is there a less expensive way to go though the transfer case and a place to obtain the proper parts ? ? ?

 

[DMgunn]

Mine had a broken input shaft flange and a bad bearing when I got it - I heard that isn't uncommon when given a (loaded) shock load. I got my parts from Memphis Equipment (Military vehicles, army surplus vehicles for sale - Memphis Equipment) and Army Surplus of Dodge City (Army Surplus of Dodge City). Both have treated me well, though I'm not sure how their prices compare - all these guys seem high to me....

 

[davo727]

I guess when its something you cant get at the corner autoparts store the guys that have it can rake you over the coals for it. The old play and you gotta pay routine.

 

[steelsoldiers]

Jason, what symptoms does your case have? Grinding? Stuck in low or high range? I rebuilt my t-case sprag on my 818 and got the parts from Memphis Equipment. I have recently purchased a bunch of parts from Clark Truck and they advertise price matching with anyone so you might give them a shout. It's not a real complex job to crack one open and work on it, but everything is really heavy and you need a decent selection of tools with access to a press.

 

[jasonjc]

A M818 I have would not go into high or low. The shift frok is held on the rail by a large set screw that should have safty wire on it. Mine was almost all the way out. Titened it back up and it shifts fine. You can check it in the truck thought a cover on the side.

 

[steelsoldiers]

A M818 I have would not go into high or low. The shift frok is held on the rail by a large set screw that should have safty wire on it. Mine was almost all the way out. Titened it back up and it shifts fine. You can check it in the truck thought a cover on the side.

Good tip for a free fix!!