Senior Member
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Join Date: Dec 2015
Location: Colorado
Posts: 1,181
Real Name: Ron
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Senior Member
Join Date: Dec 2015
Location: Colorado
Posts: 1,181
Real Name: Ron
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If you're having repeated chain failures in the tcase, you need to investigate why. Unless you are really stressing it in low-range, those things should last forever, and chain failures are very rare.
I would check for adequate lubrication first, and then, if you have it apart, make sure the the sprockets are aligned. Someone may have installed a bearing or thrust washer improperly the last time it was rebuilt, causing misalignment and early failure. There's also a possibility of an improperly assembled oil pump, leading to poor lubrication.
The fact that your shifters are stuck leads me to believe there might be a lubrication issue.
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2006 Sport Edition, V8, 206K miles, 2.5/1.5" OME lift, SPC adjustable UCA's, 255/75/17 BFG KO2's load range C @ 40psi. Regeared diffs to 4.30, with TrueTrac in rear.
1994 SR5, V6, 5-spd, Aussie locker front, Aisin manual hubs, Truetrac rear, 33/10.50/15 BFG KO's, stock suspension, OBA (Viair 400C), Front Range Offroad twin stick, 225K miles. Dual 2.28 transfer cases, for a 90:1 crawl ratio.
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