New Process 263 XHD transfer case

Performance modifications, tips & tricks

Moderators: Eric@PPE, James B., flyingpolarbear, Dev

SikSilverado
Posts: 1858
Joined: Wed Apr 06, 2005 12:52 pm
Location: DMX LBZ / Stg4 Trans / WaterInj / PPE

Post by SikSilverado »

fwiw I've had merchant's kit in there for some 60k+ Miles and I'm just over 180k now with no failures.. Driven like it's stolen since 0 MI.

Good quality part - Wouldn't be surprised if PPE's was Merchant's anyways.. Quite a few of PPE's items are other folks..

JR96CK
Posts: 1520
Joined: Fri Apr 03, 1998 8:12 pm
Location: Texas

Post by JR96CK »

Whipped383 wrote:Should also note all the gmt 800 transfercases have this problem James should make this a sticky! Iv been installing alot of these as "preventative maintnence" they are quick and easy remove transfercase stand on input side remove speed sensor and rubber plug on tailhousing and spread snapring inside and the bearing will slide out of the groove pull the case bolts out split the case throw in the case saver apply silicone bolt together get the snap ring back on plug and sensor and re install takes 3 hours tops with the right tools. Its when the cas has been burnned up from no fluid that you have a disaster otherwise they can be saved.
Question: What are you using to spread the snap ring? I keep reading that regular snap ring pliers won;t spread it wide enough.

Just ordered the MA kit, so rounding up parts to do this.

Whipped383
Posts: 2104
Joined: Mon Mar 01, 2010 9:12 pm
Location: Salt Lake, 97K1500,ECSB, 383,Whipple,0411,Marine, 03K2500,CCSB,8.1&Allison, Whipple in progress

Post by Whipped383 »

I have snapring pliers made for transmission snap rings. they have flat sides with a dimple for the ring to sit in.

JR96CK
Posts: 1520
Joined: Fri Apr 03, 1998 8:12 pm
Location: Texas

Yet Another Approach

Post by JR96CK »

Just came across this while looking through an old Sonnax catalog:

http://www.sonnax.com/product-lines/tra ... parts/2595

Whipped383
Posts: 2104
Joined: Mon Mar 01, 2010 9:12 pm
Location: Salt Lake, 97K1500,ECSB, 383,Whipple,0411,Marine, 03K2500,CCSB,8.1&Allison, Whipple in progress

Post by Whipped383 »

Thats interesting but I would think aluminum is more durable than plastic. Plus merchant warrantys your t case for life with thiers.

JR96CK
Posts: 1520
Joined: Fri Apr 03, 1998 8:12 pm
Location: Texas

Another Question

Post by JR96CK »

OK, so what about the whole broken snap ring problem some of these transfer cases have? Doe sthe NP246 Auto-Trak also have this issue? Looking in the Sonnax catalog some more, they have two kits which correct this issue. Might as well do it all while I'm in there.

100420-01K (230 Series with 1.180" Diam. Shaft):

http://www.sonnax.com/product-lines/tra ... parts/2262

100420-02K (230 & 240 Series with 1.375" Diam. Shaft):

http://www.sonnax.com/product-lines/tra ... parts/2263

Whipped383
Posts: 2104
Joined: Mon Mar 01, 2010 9:12 pm
Location: Salt Lake, 97K1500,ECSB, 383,Whipple,0411,Marine, 03K2500,CCSB,8.1&Allison, Whipple in progress

Post by Whipped383 »

That to me looks like its for the earlier GMT400 transfercases that had removabale tail housings.

JR96CK
Posts: 1520
Joined: Fri Apr 03, 1998 8:12 pm
Location: Texas

Post by JR96CK »

Just wanted to post this up in case anyone is looking for a replacement rear case half. I just found out that Dorman makes a replacement kit, about $148 at RockAuto:

http://www.rockauto.com/catalog/moreinfo.php?pk=4201551

There are also other aftermarket kits on eBay. The search for part number 12474949 yielded several results. Even the factory GM Magnesium unit has gone down in price, as it's about $283 at GMPD right now. A lot better than the $400+ it used to be.

Will cross-post in this thread too for reference:

http://www.pacificp.com/forum/viewtopic.php?p=84677

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