I just did this on my 05 a couple of weeks ago and I only have 23,317 on the odo and it had a little wear spot on the transfer case. I used the merchant automotive front pump housing, really nice piece but a little on the spendy side... Also when I did mine, there was about 5 ozs of tranny fluid in the transfer case to tranny adapter, not sure if that is normal. Also I ordered new fill/drain plugs as they are really soft metal. Merchant has them with a magnet for the drain plug. It took my about 3-4 hours to do the work, to change the front of the pump housing. I also replaced the rear bearing because I have heard the plastic seperating the ***** is known to break and ruin the bearing. It was 50 from riverside gear and the new bearing is sealed with more steel ***** to spread the load as well. If you need pics of the old one I can show you what I am talking about.

 

Its normal for some fluid in the adapter....I also striped out the drain plug on mine. Had to tap it to 1/2"npt and put in a brass end plug.

 

Thanks I appreciate knowing I am good to go on the fluid... Here is a picture of the stock bearing and replacement I got.... The stock one looks kinda sad...

 

200k on mine and it just wore the hole through...I ended up buying the new GM clip and epoxied the hole shut.

When I got the case apart everything looked new, bearings looked great everything was pretty nice as far as I could tell.

 

When I did my trans swap my adapter was dry IIRC? If there were ATF in there, wouldn't that mean that the output shaft seal on the trans was leaking, or the bushing was worn?

 

No, they always have a little bit of fluid in them.

However, if it's full of fluid, and you find the transfer case overfull, then you have a problem & need to replace some seals.

 

Ahhh, OK, good to know, thanks Roger, for confirming what Richard said I had thought that mine was clean and dry, but it was over a year ago so I guess that my memory has failed me yet again

 

Since my fluid was red and not blue it was tranny fluid not autotrac II. I might get the dealer to replace it as i have an extended warranty but it wouldn't cover the transfer case until it breaks. The merchant kit is only 100 with everything needed forthe repair. I thought that was a fair price. Also my bearing was fine with 23,000 or so miles but i heard it was an issue so I fixed it at the same time. Now I have piece of mind.... 200 for everything with fluid a new bearing and lock ring pliers.

 

Fluid wasn't included for the 100 dollar kit.

 

Both times I have had my tranny out there was a bit of tranny fluid in the adaptor, and it's got all new seals and stuff.