Finally got the transfer case out and dis-assembled. The rear thrust washer from the input gear/planetary carrier is completely gone. I found most of it in the case. The pads are also missing from the forks. I think I found most of them in the form of black "sawdust" looking material all over the T-case interior. The range and mode forks are badly worn, and will have to be replaced.

A few questions for the T-Case savvy:

The book I have does not list any clearance tolerances for the planetary pinion gears. Does anyone know what it should be?

The differential pinions have thrust washers. Will these come in a rebuild kit?

Is there any measurement/procedure to test the chain for excessive stretch?

Finally, does anyone have a reputable supplier for a rebuild kit and a couple of good used forks?

Thanks

 

Everyone loves pics:

Here is the range fork:







And the mode fork…this one might actually be OK:


Just some of the debris from the case:


This is where the thrust washer was missing from:

 

1 04638950 FORK, Transfer Case Mode Shift 2 04167969 PAD, Shift Fork, Outer 2 3 04167970 PAD, Shift Fork, Center 1 4 05003459AA FORK, Range 1 5 01664355 PIN, Shift Fork 1 6 04167969 PAD, Shift Fork, Outer 2 7 04338376 PAD, Shift Fork, Center 1 8 04167929 SEAL, Input Gear 1 9 04338891 BEARING, Input Gear 1 10 83503507 BEARING, Input Shaft 1 11 04338908 THRUST WASHER, Planetary Carrier 2
12 83503539 WASHER, Intermediate Sleeve 1 13 04796903 PLANETARY, Transfer Case 1 14 04798125 SEAL, Output Shaft 1 15 02466224 BEARING, Output Shaft 1 16 04269189 BEARING, Output Shaft 1 17 05003453AA CHAIN, Transfer Case 1

These are Mopar numbers. The mopar manual doesn't the tolerance for the pinion bearings.

 

Looks like at least $400 just for the forks and planetary. Since I haven't been able to even road test the D to check the tranny, I'm going to R&R the transfer case with a JY unit for $175. It will have a 30 day warranty so at least I can make sure the transmission is OK before I dump a ton of money into it. With winter coming I only need it to hold together until spring. If it works out OK, I can spend the winter hunting down those clearance specs and the chain specs, and any other info I'll need for a proper rebuild. I'll be rebuilding/replacing the tranny in the spring anyway. After all, it does have 224,000 miles on it.