I just found a hole in my transfer case that is about 1inch by 1/2 inch. Can I just weld it or do I need to replace it? How hard is it the change it if needed? Thanks

 

what caused that, was it internal?

 

You need to find out if somthing broke on the inside and put the hole from the inside out or did you hit something and cause the hole?

 

^ is there a echo?

 

The best I can tell, it broke from the inside.

 

I would probably replace it. Does the T-case still work? I don't think you can weld on cast. It's not that hard to replace, Remove drive shaft's and Take something and knock something like 6 bolts out and it will come off.

 

No, its not really working now. I had to move it so I could get my our vehicle out, and it moved Very slow/hard and made a horrible sound. Should I go new, rebuilt, or maybe even a used one? How hard is it the swap?

 

Swap won't be that just takes some patients if you don't have the right tools. I had to remove mine when I took the tranny out. Of course if you have power tools it will be easy, along with the right sockets etc.. I had to remove the t-case using a 5" long wrench. (Very short took some time but I got it.) While your under there check your play in the drive shaft on the joints and if they are bad buy some new ones... maybe even just replace now while your there.

 

Try calling some local junk yards. If not, you can always buy a remanufactured one or one off of a wrecked truck from eBay.

 

Thanks, I will be giving it a try on my next days off. You say I should go ahead and replace the joints, anything else I should do while I'm under there?