So...about 120 miles into Baja California, Mexico, I got banging, grinding, and spinning out of somewhere in my driveline. I cracked the rear diff and all seemed solid there. The driveshaft were good. The transfer case...uh oh, no fluid! The Mexican people were great; I got a tow back to the border for cheap and was able limp back across and catch a AAA tow back home.

Cracking open the TC, I found a lot of metal shavings and a fork that was whittled down to almost nothing. Part of the input gear was also munched on greatly.

I have 3 questions for the group:

1. How could this happen? (I mean, other than no fluid.)

2. How can I prevent it from happening again?

3. Where can I get quality parts at a decent price? (Input gear, shift sleeve/slider, low range fork) And other than a rebuild kit, is there anything else I should get? Like the pilot bushing?

I *could* get a donor TC from a yard or a rebuilt from some company, but you really don't know what's inside the case. And I'm tired of getting screwed with, so unless it financially makes sense otherwise, I'd rather do the rebuild myself.

Thanks for your input.

Ian
'96 XJ

 

A side by side of the good fork versus the bad fork. I believe they are supposed to be the same thickness.