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previous post wasn't 100% clear. The thermal-actuator-spacer was installed with an updated-electrical-actuator, so the selector fork was not sitting right. Operating the actuator with the axle tube off of the diff showed that the spacer put the fork out even in retracted mode. Note the wear...

This. This spacer is for the thermal actuator. I bought the truck around 2004 with 60k miles. Couldn't engage 4wd so a local shop debugged and fixed or converted it to motor actuator. He complained that the wiring was yutzed up and it cost him overtime to straighten it out. The enclosed...

No apparent damage to the fork mechanism. Also, the fluid drained out with no residue other than the general gross old appearance.

1997 GM C K2500 4x4 with 6.5td, 160k miles Over on another thread I've been dealing with various leaking seals. Can't explain this one. Have the front driveshaft off, the diff is definitely engaged. I removed the actuator (upgraded from heated to motor drive). It stayed locked for a while...

I very much replaced the following things between the transmission and tcase: transmission output shaft tcase input shaft (it sits in a bolt-on carrier which facilitated the work) a paper gasket on the tx/tcase adapter a large o-ring on the tx/tcase adapter A local transmission shop...

Strange observation: there was no indication of leaking in the space between the transmission tail and the transfer case adapter. I replaced the transmission output seal and tcase input seal anyway. The tcase was definitely overfull. Could the extra fluid get there by way of the vent tube?

dunno if anyone is still following my foibles, but: About 75 miles ago I replaced the transfer case front and rear output seals and rotated the rear shaft/yoke 180degrees. The tcase is dry, the diff input seals are holding, and the rumble doesn't come on until 50+ mph. So, I will still be...

This 3/4 ton 14 bolt diff model indeed had nylon u joints on the FRONT driveshaft but the rear had outside clips. still looking for other references about this on the internet. no one seems to know about it

Took it out for a test drive. At 45mph and up there is a new low pitch rumble. Perhaps the rear drive shaft got imbalanced or the u joints aren't perfectly centered? They appear to be fine. This drive shaft has a u joint at the diff, and another one at the sliding yoke at the tcase. no center...

I have most of it apart and am doing some "while I'm in there" extras. Driveshafts and tcase are out. Some of the u-joints are completely removed. Rear Diff yoke is coming off tomorrow due to leak. Maybe front diff yoke too. Pro tip: unbolt cross member, lift tcase/trans, slide cross member...

Indeed, removed the top plug from transfer case and a good amount of fluid (1/2 to 1 cup) came out. I have a 250 + 250 mile trip tomorrow. Assuming I keep checking transmission level every 200 miles, can I keep going until I can pull transfer case? If this is dicey, I can just take another...

I dropped the pan today. The fluid is 100,000 miles not-fresh but not abysmally stinky, burnt, or gritty. The bottom of the pan had no solid matter at all. The magnet had only the lightest coating of grey stuff, whatever it was, it was very fine and small quantity. Pulled the TC cover down a...

Truck is a 1997 K2500 Suburban, 6.5TD, 4x4, 4LE80, 160k miles, very little towing, mild climate. Many years ago I put on a very stout aftermarket transmission cooler system. I often put the shifter into 3 or 2 around town just to take a load off the brakes. Gentle but firm with the shifter...

For Sale: 1997 K2500 Suburban SLT 4x4 6.5td, 160,000 miles, $7000.00 1997 GMC K2500 3/4ton Suburban SLT 6.5TD TurboDiesel 4x4, 160k miles, $7000.00 Located in SF Bay Area, willing to deliver within a 500 mile radius. Northern California car all its life, zero rust, great paint. Fastidious...