Last edited by 03zx6r; 03-12-11 at 08:54 AM. Reason: failed link due to insufficient post count
Excellent writeup, JD. Thanks for sharing the knowledge! I replaced our case chain two weeks ago and the car's running great! Wish I'd have done it earlier. My wife was nervous before I started, so I called the local GM dealership to discuss this problem. They informed no recall and won't give us a break. Further, they do no transfer case repair in their shop but only replace the entire case at car owner's expense. Their ignorance and this write-up made my decision final. We still have the tailpipes off so it's loud to run right now, but 4 exhaust bolts broke off upon removal so I'm still waiting on that order.
Here's some pictures to help anyone else. I referred to them a couple times as well as a service manaul I bought online with diags while putting our case back in the car. I'd have to agree the hardest parts for me were getting the case free from the transmission as well as splitting the case which was also tricky. It took me a little longer doing the whole project because I didn't have access to a lift and worked in only 2 feet of clearance (2 floor jacks and large oak logs to help support heavy front end). Estimation of 6 hours for removal, 3 hrs splitting case/new chain/gasket seating scrub, and 3 hrs mounting back in the SRX. I spent one Saturday removing everything. Split the case the following day then ordered the chain from Cobra. It took a week to arrive as they had it on back order.
Feel free to ask any questions.. The picture link below points to snapfish so you may have to open a free account to view (only takes a minute). I also have a video clip of the northstar with exhaust pipes dropped if anyone wants to hear it. Nice sound but ear piercing to drive. Good luck!
Oh yeah, in mine as well.. sprockets looked brand new and we have 108k miles.
Great Pics. I'm going to tackle this on Sunday, or atleast start it. Thanks for the DIY and photos. How does the chain pull off? Do you just pull up on the sprockets and they slide right up?
Hi!, yes just pull up sprokets.
Best of luck. Once the case is split, it becomes clear how easy everything is.
Good job boys but, it's a lack of testing from Borg Warner...
I have a brand new chain I am looking to get rid of if anyone is looking to do this repair themselves. I'll sell it for $149 shipped! A price that can't be beat.
I bought the chain from Cobra Transmissions (ebay) about a year ago to do the rebuild myself as well. But once I got the transfer case out and split in half, I chickened out and just took the transfer case to a transmission shop and had it fully rebuilt with new seals, bearings, and chain (sold to me as a kit, thus my having this chain leftover to sell).
Good luck with the rebuilds guys!
Is the chain still available?
Very nice write up!! I'll be using it this week end.
Just one Question..I'm not really that skilled in awd or even 4x4..
when u say "After they all are removed, CAREFULLY take the two parts of the housing apart. If one part of the housing is removed vertically, all the gears can fall out, and you wont know which order to put them in. So, take it apart horisontally"
do you mean the same way it is positioned installed??
I'm a caddy newb..
1981 El camino..
2005 srx v8 awd aka head ach!!
im interested in the chain i was gonna order today!!
Yes, the same way it is positioned installed.
About step three in the write-up. Make sure to put a jack or something under the transmission pan to support it when the suppportplate/assembly is released/removed. Othervice, the transmission will only be supprted by the engine-mounts which is not good.
Excellent work and great writeups. Thanks guys.
As an old transmission guy, I can say based on the sludging inside the case that these t-cases are running pretty hot.
You need 250F (usually more) to cook the Dexron enough to start leaving deposits like that. Of course the oxidation reduces the lubricating properties of the fluid too.
I'd prescribe a fill of synthetic Dexron (Allison TES-295), Amsoil, Mobil 1, etc. Based on these pics, I'm definitely doing a fluid change on my 50,000 mile car.
Thanks for this post. I too feel and hear a popping noise when accelerating from dead stop. Have to feather the pedal to not feel and hear it. Read all stuff on internet and came to conclude it would be the transfer case chain. I bought the chain and the 2 gears from Cobra Transmission in Florida, I am in California. Who would know years later that I will be looking at your writeup to help me repair our 2004 SRX V8 Northstar. JD2004 and 03zx6r did a good thing here and I appreciate you sharing. I am going on this venture as well today, I got 3 days to make this happen. Hopefully it doesn't take me more than 2 days.
Last edited by fgamulo; 06-08-12 at 12:32 PM.
Fgamulo, thanks and good luck with the repair!
I am trying to tackle this job, but the one gear will not slideup? any thoughts. The planetary gear comes right out, but the other one wont budge. Any thoughts would be great.