I doubt that it is a problem internal to the transfer case. This code can happen when there is corrosion at the TCCM or encoder motor. It can also happen when/if the encoder motor itself becomes weak. The proper operation of the sector shaft can be determined by removing the encoder motor and rotating the shaft into one of the detent positions, latching the front axle engaged (just bypass the vacuum solenoid on the firewall, splicing the vacuum lines together) and test driving on a low traction surface.

 

Well, here we go. The Chevy guys have stripped the transfer case to find the clutch band thing-a-ma bobs are burnt. The case thing in witch they are in is evident of serious overheating.

Anyway, they advised the insurer that it needs a new set of these clutch things & parts need to be imported from stateside. Parts = $1900 odd & labour around $800. As an alternative, they had a 2nd hand unit which does work ( remember, these guys import fully working & good order vehicles to be able to provide replacement parts for these Jap imports) & offer a 3 month warranty, which is what one gets when buying any Jap import. SO, they agreed to simply replace the tcase @ around $2500 + GST (12.5%). My cost is $350 for the excess. I only get the beast back Tuesday. AND the next weekend is ALSO a long one, so I'm going off road!

PS. The electronic shift motor whichalsodid not workwas replaced & the quoted price included a new one.

 

Remind them to fill it with AutoTrak2 fluid ONLY or you may be looking at another replacement...

 

Good idea. I'll phone them first thing Tuesday. IF this stuff's available in NZ. The mechanic is an American dude (& did his trade there) so should know the product.

 

I've just picked up my truck this afternoon. Seems to work. Switched from 2hi to 4hi & back couple times, seemed to work ok. Will be off-roading this weekend, so look out for pics.

Oh yes, Kyle. They did clean out the t/case & fill with Autotrak2. From the look I got when I asked I think they thought it was a dumb question. LOL