well nova nailed it, i think i was right too. so after calling dealers trans shops and the very busy dwayne at the off road shop i use. it seems that when i shredded the boot and damaged the sensor, my clutch was'nt applying all the way and eating itself. nova was the only one who thought it could be the clutch. everyone else said " oh we never see those go bad" well mine must be toast judging by the metal flake, black, stinky fluid i drained today. going to crack it open tommorow and see the extent of the damage. very dissapointed with the design. it is " more than i need, and more than i expected" [gm ad capaign] . what a girly little bitch unneccesarily complicated pos transfer case. never never again. umm, anyway, i'll let you know what happens. oh, nova do you know of any non sissy transfer cases that will swap into my rig, without costing 10 grand, and without a team of nasa engineers to figure it out ? e

 

I think Parish8 on this board has something different in his truck and the encoder motor is just tied up under the truck to fool the computer. I have a Denali transfer case which has a fluid filled viscous coupler instead of clutch packs. I dont remember why it was removed at work so I would need to take it apart and check. Maybe you could fit an aftermarket Atlas t case under that thing, those are Bulletproof.

 

thanks, i was actually looking at an ad for atlas wondering if i could make it work. between the transfer case, adaptors, driveshaft, u-joints etc i'm wondering what the cost would be. was looking more for a semi direct replacement. is the viscous coupler any better than the clutch ? my shop is ef'in me around, went there on tues. because he had a donor encoder motor, that did'nt work [had to put it in myself cause he was too busy] went back wed. waited 2 hrs to get on the rack. pulled the case, i left assuming he'd tear in to it and order parts. he took it apart at 7 that night [ blew it off as soon as i left] too late to order parts. odered parts the next day from his flaky source. promised too call me back three times. no call. going in tommorow morning, he'll either get on it or put it back the way it was, so i can go somewhere else. if you don't hear from me for awhile, it did'nt go well. i'm a very patient guy but when people don't call me and let me know what's going on i get enraged. my weekend is already ruined as i was supposed to leave with a group tomm morning. gotta find a new shop as i will never consider going there again, i'll pay ten times more before that happens. sorry about the bitching just needed to vent. e