2003 Chevy 2500 HD Transfer Case Question
 

Have a 261HD transfer case for the above truck that let go. It had the dreaded oil pump moving around problem that wears a hole in the transfer case. About a year and a half ago, it developed a small hole and blew all the ATF out the case. JB welded the case back together and added fluid. Worked fine till last week when pushing snow, it died. Took it out of the truck and split the case. Am trying to get the oil pump and shaft half out of the case, but it won't slide. The breakdown looks like their is a clip behind the oil pump, but you can't get to it till you get the shaft slid out. I can't het the shaft slid out. Any tricks to this??

Again, this is the 261HD transfer case, which has the manual engagement in the cab, not electronic. Any help appreciated. Thanks, JOHM

Found the acces hole for the clip. No brainer really, just was'nt paying attention

Ah............The dreaded "pump rub" issue !

Did you buy the kit that fixes the prob? I had the same prob on my son's Tahoe. Put in the kit for $70.00. Permanent fix!

This effects all late model New Process GM cases in both the 1/2 and 3/4 tons.

The dreaded issue and the Merchant Auto "fix kit cure" link
http://www.merchant-automotive.com/t...grade-kit.aspx

That's the kit I used. However, the real trick is to install it before the problem surfaces. Before the the hole is worn through. But, it is real quality piece. Plus a relatively easy fix for anybody mechanically inclined.