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'04 3.5 4X4 transfer case output bearing replace

2.6K views 2 replies 3 participants last post by  WV NATIVE  
#1 ·
My truck has been making a squeak, squeak, squeak when taking off and getting faster and faster and goes away at around 20 MPH. It gets faster with speed and will go away if I take my foot off of the gas pedal or if I put it in neutral while rolling. I jacked up the rear end of the truck and running in drive I can stop each one of the wheels one at a time and the noise is still there, so it's not a wheel bearing. I determined that the noise seemed to be the front universal joint, but the closer I looked, I'm pretty sure it's the output shaft bearing on the transfer case. This is my first 4 wheel drive truck, so I'm not that familiar with them, though I did replace all the bearings and seals in the front differential when it sprang a few leaks and one needle bearing came apart. I guess my question is, can tailpiece on the transfer case be removed, or does the whole thing need to be removed and split apart?
It's late and dark outside, but I'm looking at pictures and it looks like the tailpiece can be removed and the bearing and seal be replaced on the workbench instead of having to remove the entire transfer case.
Please tell me that this is the case and this is a pretty easy task!!
Thanks for your help guys. Trying to keep this 205,000 mile "Yella Fella" in tip-top condition!

I pulled an F-150 crew cab out of a mud bog last week! That was a blast!!
After several days of afternoon thundershowers here in Savannah Georgia, I went to a local landfill to dump a load of lawn clippings. The whole place was a swampy, muddy mess. The guy with the F-150 beside me asked: "You think we're going to be able to get out of here?" I finished before him, put my truck in 4 wheel drive low and eased out with my 8' trailer in tow. No spinning, no problems. When I saw he was having problems, I disconnected my trailer and backed up to him and put a heavy ratchet strap around my trailer ball and around his front tow hooks. He suggested that I pull out of the mud as much as possible so we wouldn't both get stuck, but I told him I was pretty sure we were good. I told him to just put his truck in neutral because it was a short strap and I didn't want him running into me. I put it back in 4 wheel low and eased us both out of the mud. There were several other guys around in their trucks waiting to drive into that swamp and dump their lawn stuff and I got quite a bit of cheers from the crowd! It was great! as we disconnected, and the guy was thanking me for pulling his bright shiny new Ford truck out of the mud, I said: "These tow hooks on the front are pretty handy!". One guy with an F250 4X4 Diesel asked if I could hang out a while in case he needed help. I laughed and told him I think he would be okay!
My little 14 year old, yellow, 5 cylinder truck was the hero at the landfill! You gotta love that!!!
 
#3 · (Edited)
I guess you could split the case with it still in the truck. At least I don't see why it couldn't be done. I've never really thought about it until you brought it up.

It's honestly not difficult to remove the entire unit. Its kinda messy though. I didn't think transmission fluid would ever stop draining out when I pulled mine. I had tranny fluid everywhere. The transfer case itself is pretty light and a man can pull the whole unit out by himself without a transmission jack.

I'd think it would be easier to buy a low mileage case off ebay and swap it out. The T150 isn't really worth rebuilding. I don't even think you can buy individual internal parts cheaply anywhere.

I read on 355nation somewhere a few years ago that our transfer cases are like girlfriends.

Run em until they get noisy and trade em out for a new one.

Good luck.