Rebuilding a GM HD263 Transfer Case 

I'm glad it helped!

I'm glad it helped you in your project!

Fantastic!

Thanks brother! Good luck on your journey!

That's the name of the game...

Thanks brother!

Sure thing!

Oh yes. Still here. Life happens...

Fantastic! I hate having something apart for long periods of time waiting on parts...seems to be more common these days at work too...

Well maybe you can help me I have 4 high and 2 wheel drive but it doesn't want to go into 4 low got any ideas I have pulled it back apart and checked everything as far as I can tell it's all correct

@@jasonbayer2096 Is your foot on the brake and transmission in neutral when trying to make the shift? Does the light on the shift button just flash at you when you push it?

Its there...

Send me a pic of the clip to my email at irocinz@gmail.com. I'm sure if I seen it, I'd recognize it. And yes the gears will not be inline with the case off. They will line up when you assemble the case and get your output bearing in the snap ring.

Not without changing the input shaft, not to mention I don't think that case would hold up to the torque of the D-Max ...

I think Syncromesh is overkill. I recommend Dexron III but a synthetic. I like Amsoil products. Never had a problem with their oils...

Ideally, you want the transfer case and the encoder to be in two high or neutral.

@@IrocinZ Thanks for the quick reply, transfer case is in 2Hi now but not sure of encoder motor. Could I plug the encoder motor and try switches without it being installed on transfer case.

Yes, if it fits. I would recommend it.

Reluctor itself doesn't use a snap ring that I remember...

Lots of practice...

Very similar. Different manufacturers but similar designs

They will have slack when you split the case, but if you have too much bow, then the chain and gears should be replaced

Anything is possible. Main thing is to make sure the encoder is correct for the transfer case. Sometimes you might have to rotate the shaft a little to get the encoder to set down on there. Whatever you do, don't force it...

@@IrocinZ thanks for the reply... We actually have 3, yes3 encoder motors, two are brand new and one is the original. We did try what you suggested a day or 2 ago but it didn't work. The only way we got it to fit was when the transfer case was in 4 high and the encoder motor was in 2. But, it did not shift out of 4 wheel and of course did not work at all really. The new motors have a shipping alignment plug sort of thing to ensure the new moter is clocked correctly....2 wheel drive.

@CS I would then try rotating by hand and see if it goes in that way. If so and the alignment is still off, pull the tcase apart and make sure internals are correct and nothing broken...

Sound kind of odd...Reverse is a band inside of the trans. Kinda leaning more towards an issue with the internals of the transfer case, especially with black fluid...

@@IrocinZ the tailshaft wiggles alot side to side and in and out on the tcase thinking bearing is shot on tailshaft everything else seems smooth and there was like maybe a cup of black and grey fluid i gotta take it apart tomorrow

@Macdonald 1997 Yeah, I'd be looking for a hole in the case where the pump rides. Sounds like it was starved for lubrication which is so common...

The sun gear and range hub were stripped going in the reverse direction would bit together just fine in drive just in reverse they were angled and the range hub would pop out and the fork pads were gone and kinda thinned down the forks themself

​@@IrocinZdoes the output bearing snap ring sit in that top groove when its on the bearing or can it sit when its on the bearing on the ledge on the bottom i would like to send u a pic if your confused to what i mean

Yes. The components of the XHD are bigger tho, but the process is the same

I'll have to let you know when I can get to the parts catalog. It won't load here at the house. I do believe they are, but I want to verify it.

@@IrocinZ ok thanks much appreciated 👍

@Adam Strickland The case halves are different between the 246 and the 261-263 for the sole reason the 246 has three speed sensors whereas the 263hd only has 1. The rear case half is also different between the XHD and the HD, the Allison and the 4L80e. Hope this helps

I do believe you can snake that seal out and in. Never tried it with everything together...

@IrocinZ I sure hope so, I've looked and looked and no 1 has a video on it. Someone said its a sealed bearing but I'm not sure, thank you for your reply and your video is really good, makes me wanna tear mine apart over this annoying leak

@bravojuan559 if iremember right, that is a bearing and seal assy...

@IrocinZ I'll look into it today, it's the only thing leaking on my 263, I really don't wanna drop it

If you still have the New Process transfer case, there is a shift shaft seal and a gasket that seals the shaft and the encoder motor. They are available separate but may have to get them from the dealer...

@@IrocinZ thank you for the info, happy holidays man ..

@@thuggmtz You too brother!

Goes on top of the sun gear

@@IrocinZ Yep, and one goes inside the planetary and the input (sun) gear goes on top of it. And one goes under the steel tabbed washer/end plate and snap ring, or on top of the sun gear like you said. Point being is that the other one farther inside is just as important. The GM parts counter diagrams in use today say 2 required. And that is why the 2 groove channels go all the way through the inside walls of the planetary cage to the bottom. I just disassembled one the was repaired by a tranny shop and they used smaller one on top of the sun gear and it broke apart into pieces in less than 1 year. The one tabbed correct one under the sun gear broke into bigger section pieces too. The skinnier one for the top was also had a bigger inside opening. So rattled around at times vibrating and such. It had a howl in mostly in 1st and and lightly in 2nd gear with normal acceration and quieted as the speed increased. No noise when in 4WD though.

@@milwaukeebiker You are correct.

Is there another name for the “sun gear” I don’t know what you guys are talking about there. I’m trying to figure out where the thrust washer goes. I didn’t take apart my planetary so I’m only replacing the other one

@@EgoDeath144 Think of the solar system. The sun is in the middle and the planets rotate around the sun. So the Sun gear is in the middle, and the planetary rotates around the sun gear. On the outside of that planetary will be a ring gear. Does that help?

Merchant automotive or transmission parts distributors is where I recently ordered stuff.