I have had the transfer case replaced 5 times in the last few months. Sometimes it will work for a couple of weeks but other times it will not work as soon as they put it in. It will engage the 4 wheel drive sometimes but most of the time it will not. The dealer keeps saying they are getting bad parts from the supplier. There is also some significant discoloration like it has been getting hot on the front axle between the differential and the right wheel. THe dealer thinks it is unrelated or as a result of my transfer case problem but I wonder if it is not the cause of the transfer case not working. they also tell me there have been other trucks this model that have required multiple transfer cases as well. I am at a loss where to go next. any advice would be appreciated. I do have a lifetime powertrain warranty so these are covered but I need a 4 wheel drive truck and do not have one.

 

Why not have the shop rebuild a transfer case? They arent complex.