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  1. tobyS

    M809 series 5 ton transfer case issues

    Yes, sudden major looseness seems really unlikely with a properly functioning bearing. And sure, $500 seems like good insurance if it's not in the same condition. It's not too high stakes of gamble. feel the output and input for play and rotate it feeling for "smoothness" (no grinding or...
  2. tobyS

    M809 series 5 ton transfer case issues

    His comment that the rear output shaft can be moved around by hand and that the seal has given up, means the flush is not going to do it. flushing is something that I would do after knowing weather the bearing can be tightened or if it is toast. If there are parts of that bearing in the TC...
  3. tobyS

    M809 series 5 ton transfer case issues

    If it ate the bearing, it has to be split. If it's only adjustment, which is what I would try first, you can probably try that in the truck. I would have to do some research. It's several years now and I can't remember it the output is adjusted from the front or back. The guy I bought my...
  4. tobyS

    M809 series 5 ton transfer case issues

    Unhook the front and rear driveshaft and back off the emergency brake, so you know it's not the noise maker. See if the rear output shaft can be moved up and down by hand. Run the truck in gear and see if the TC is the noise maker. Unfortunately when I had mine completely out and apart I...
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