Has anyone rebuilt an LT230 transfer case?

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Jeff Blake

Well-known member
May 6, 2016
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16
Pacific Beach, San Diego
I picked up a leaky 04 transfer case that I need to reseal at a minimum before adding CDL to my '02. I bought all the gaskets, seals, and 8 or so Timken bearings. Obviously I am going to clean and inspect the gears first. But I kind of just want to rebuild it for fun, HOWEVER, skimming through the manual, there are mention of at least a couple dozen LRT tools. When I rebuilt the engine, there were maybe 6 or so LRT tools, but they were all pretty optional.

Thoughts, advice, tips?

Since I have 32" tires, and might go bigger, should I regear while I'm at it?
 
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robertf

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Jan 22, 2006
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in the middle of one now. I think I spent 4 hours last weekend shimming,measuring,disassembling,reassembling the differential

If you're just doing bearings and seals you shouldn't have to mess with that, but I did a 1 piece cross pin and new thrust washers

only specialty tool I've needed so far is a fish scale
 
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discostew

Well-known member
Sep 14, 2010
7,727
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Northern Illinois
You should keep in mind that robertf has rebuilt steering gearboxes and other crazy stuff. So him saying easypeezy isn't much comfort to me. Just saying.

I find the leaks are usually the o rings on the countershaft and the input seal. Sometimes one of the output seals. The service manual that's going to be the most help for you will be the overhaul manual for the t case. It's a different book than what they consider the service manual.
 
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discostew

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Sep 14, 2010
7,727
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Northern Illinois
I would tell both of you to pay close attention to the preload on your countershaft and make sure you get that right. If you get it right the t case will be much quieter. When it comes to drivetrain noise, preload is your friend.
 
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Jeff Blake

Well-known member
May 6, 2016
429
16
Pacific Beach, San Diego
Thanks for the advice... I'm not afraid of some precision work... when I did the engine rebuild I followed and checked all the measurements with micrometers, dial bore gage, dti, etc. it's the specialized tools that concern me and how much more of a pita it would be without them. I don't have a press either
 
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Jeff Blake

Well-known member
May 6, 2016
429
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Pacific Beach, San Diego
Definitely need a press.

Should I regear the case while I'm at it? If so, any recommendations? I'm running 32" tires 235/85r16. Stock axles/diffs. I may be interested in lockers at some point.
 
Jimmy

Jimmy

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Apr 10, 2006
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Aurora, CO
Jeff Blake said:
Definitely need a press.

Should I regear the case while I'm at it? If so, any recommendations? I'm running 32" tires 235/85r16. Stock axles/diffs. I may be interested in lockers at some point.
Click to expand...

If you're not having significant issues with the gearing you currently have, I'd say just leave it. If you think you will be going taller with the tires at some point, you may want to toss in the 1.4 high range gear. But since this does nothing to change/improve low range performance, you may just want to consider ring and pinion swaps in the future instead. Low range gears for the t-case are pricey.
 
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Jeff Blake

Well-known member
May 6, 2016
429
16
Pacific Beach, San Diego
I think i have issues with my gearing. I have a newly rebuilt 4.0L (valve job, flanged liners, performance camshaft, etc) and its a DOG to get up highway grades. East on 8 in San Diego, I think its 6-8% grade, and I have a hard time maintaining 50-55mph @ around 3-4k rpm. It feels like I'm towing. On the other hand, on level surfaces and accelerating through stop and go traffic, it's very snappy. Is the gearing my issue now that I have 32" tires and a lot more weight (front/rear steel bumpers, rock sliders, fridge/cabinet system, on the plus side I have deleted 2 rear seats)
 
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SMLE

Well-known member
Aug 21, 2014
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GA
Ha, if you're talking about that grade leading up to Alpine, I used to do that every day in an old Wrangler. Felt like I had something behind me trying to pull me back down the hill...
 
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Jeff Blake

Well-known member
May 6, 2016
429
16
Pacific Beach, San Diego
Exactly... well I've been playing with the ratio calculator: http://www.ashcroft-transmissions.co.uk/calc/ratio_calc.html

And with my current setup, I definitely need a regear with 32" tires. The only time it appears to make sense to regear the transfer case is if you're running 35" tires, but its still optional. The best bang for the buck is definitely regearing the diffs. Putting in 4.11 the diff looks to be right move.
 
Mongo

Mongo

Well-known member
Apr 19, 2004
5,731
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Jeff Blake said:
I think i have issues with my gearing. I have a newly rebuilt 4.0L (valve job, flanged liners, performance camshaft, etc) and its a DOG to get up highway grades. East on 8 in San Diego, I think its 6-8% grade, and I have a hard time maintaining 50-55mph @ around 3-4k rpm. It feels like I'm towing. On the other hand, on level surfaces and accelerating through stop and go traffic, it's very snappy. Is the gearing my issue now that I have 32" tires and a lot more weight (front/rear steel bumpers, rock sliders, fridge/cabinet system, on the plus side I have deleted 2 rear seats)
Click to expand...

you've got something esle going on...drop from Drive to 3rd and see if it shifts. I could do 75mph all day long with 37's, 1.4 hi gear and 4.11 in the axles and maintain 65 on hills with a stock motor,

Under drive ain't gonna buy you anything at highway speeds
 
p m

p m

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Staff member
Apr 19, 2004
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Mongo said:
you've got something esle going on...drop from Drive to 3rd and see if it shifts.
Click to expand...
+1.
50-55mph at 4k rpm may mean you're in the 2nd gear already.
I have 1.4:1 in t-case in my white truck, and it only needs to be dropped into the 2nd going up 395 uphill from Bishop. East on 8 is smooth sailing with an occasional drop into the 3rd.
 
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Jeff Blake

Well-known member
May 6, 2016
429
16
Pacific Beach, San Diego
Mongo said:
you've got something esle going on...drop from Drive to 3rd and see if it shifts. I could do 75mph all day long with 37's, 1.4 hi gear and 4.11 in the axles and maintain 65 on hills with a stock motor,

Under drive ain't gonna buy you anything at highway speeds
Click to expand...

Well, 1.4 tcase gears and 4.11 in the axle for 37" is a pretty good fit

Im running stock 1.22 hi and 3.56 in the diffs. Couldn't this account for my problem? I'll have to try downshifting on my next outing. What exactly am I looking for? Honestly, I know a lot about the engine but I know jack squat about transmissions, tcase, gears, etc

'04 t-case arrived today to start my CDL swap. Unfortunately the captive bolts in the flange speared the rear output housing during shipment. I got my money back, and have to start the search again for a transfer case. At least I have something to tinker with. I looked up prices on FTC5095 (rear housing) and its $300+ so that option is out the window... I can get another transfer case for that much.
 
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