So I?m thinking of doing the LT230 swap. The problem area seems to be at the input gears where the transfer case and transmission connect. All the noise is coming from that spot. What do you think that could be? Hopefully it?s not the main shaft from the transmission. What would just be spinning in place in the transfer case? Gears worn down? Chain? Chain would be a different sound I think. When I was driving and this happened it was all of the sudden no gradual problems.First off, the ODO has to pass a million miles to "roll over" so you probably have only the 82K on it.
Second, The transfer case is probably the original Borg Warner so there's no diff lock.
I have had this happen in one of my previous RRC loobs. On Christmas Day pulling out of the Chinese restaurant (it was packed with people by the way!). It was accompanied by a pretty good bang. I never actually diagnosed the problem but I'm pretty sure I broke the drive chain in the transfer case. That truck went straight off to be parted out by my buddy Rob.
So I would plan to get the transfer case out of there. This is an excellent opportunity to switch to an LT230. You will need the shifter off a D1. If you can find a transfer case locally then this shouldn't cost you anything more than a few hundy and some elbow grease. Repairing the Borg Warner will be, to say the least, expensive. Possibly even impossible as the parts are really difficult to come by. The viscous coupling I mean. There's no point in rebuilding without putting in a new VC and they just aren't out there.
So, happy wrenching!
What year of the LT230 would I need and do you have any tricks or tips in getting the tcase out?
Thanks so much.