4WD Transfer Case Cost and Guide

What is a “New” 4WD Transfer Case?

“New” transfer cases can only be found in brand new cars rolling off the assembly line. From the metal case and gears, to the springs and seals, every component is freshly stamped, extruded, or otherwise created.

Car manufacturers do not sell or distribute these “new” transfer cases. All other transfer cases out there are either rebuilt, used or remanufactured. Even if you have a transfer case replaced under warranty by a dealership, it will be a remanufactured 4WD transfer case.

What is a Remanufactured 4WD Transfer Case?

A remanufactured transfer case refers to a 4WD / AWD case that has been completely disassembled and then re-assembled on an assembly line. Each component is inspected, cleaned, and reconditioned by a technician that specializes in that particular stage of the process.

All of the critical elements are tested to ensure that they meet original equipment (OE) tolerances and standards. Any part that doesn’t meet the original specifications is either machined until it does or replaced with a brand new part.

Once all of the components meet specification, they’re sent down an assembly line and the transfer case is reassembled. The reman case is then put on a machine which simulates real-world driving. This allows leaks and imperfections to be discovered and dealt with before the transfer case leaves the factory.

Another benefit of a remanufactured transfer case are the updates and upgrades it receives. Once a certain vehicle model has been in production for a few years, small issues with the design are discovered and solutions are implemented. It may be more robust friction materials, stronger seals, stiffer springs, or number of other things.

Everything from the metal thickness, to the rotational torque specs, are taken back to the exact same point as they were, when your transfer case left the factory the first time. A remanufactured transfer case can also be modified during this process, to correct for known issues that could adversely affect its long-term durability.

How Much Does a Remanufactured Transfer Case Cost?

On average, a remanufactured transfer case costs depending on the make and model of your vehicle. The cost of labor to install it is in addition to the price of the unit and will typically run between $400 and $800.

Transfer cases can be purchased through Autozone and Advance Auto Parts.

Remanufacturing Process – What is Involved?

1. Disassembly
   When a “core” (i.e. used) transfer case first arrives at the remanufacturing facility, it’s catalogued and completely disassembled. All of the parts are accounted for.
2. Cleaning
   Once all of the internal parts are catalogued, the old bits of gasket are thrown away, and parts like the gears, case and shafts are washed in a high-pressure parts washer.
3. Inspection
   Once all of the gunk has been knocked off, the parts are thoroughly inspected for cracks, imperfections, and adherence to OE tolerances. Parts that don’t make the grade are either machined back to factory specs, or replaced.
4. Replacing Parts & Re-Assembly
   All components that don’t meet specification get replaced on the assembly line, along with all seals, gaskets and o-rings. Electrical components such as solenoids and control units get inspected and replaced. Upgrades and updated components are installed, then the transfer case is re-assembled using the proper OEM torque specs and fasteners.
5. Testing
   After assembly, each and every remanufactured transfer case is placed on a machine, and put through a series of driving simulations to test the operation, and quality of the transfer case. If any leaks or faulty parts are discovered, the transfer case is sent back through the remanufacturing process.

Benefits

Done in a Factory Setting

Remanufactured transfer cases are built in a factory, on an assembly line. Technicians specialize in specific areas, and each transfer caseundergoes numerous quality checks throughout the remanufacturing process. This ensures a higher quality product, and longer service life.

Replaces More Parts

A remanufactured transfer case is thoroughly disassembled, cleaned, surfaces are machined to factory specification, updated parts are installed, and an entire list of components are replaced. By comparison, the typical rebuilt transfer caseonly receives new components if the original is worn out.

Testing

When a mechanic or repair shop rebuilds a transfer case, it’s usually tested after it’s reinstalled in the vehicle. By contrast, remanufactured transfer case are subjected to a rigorous battery of tests before they ever leave the factory. Dyno machines and valve body testers are designed to expose problems before you get on the road, that way you won’t have to take your vehicle back to the mechanic because “something doesn’t feel right”.

Warranty – What is Covered?

One of the biggest advantages to buying a remanufactured transfer case is the warranty. A good quality reman transfer case will come with a 3-year/Unlimited Mile Nationwide Warranty. Anything less should make you question the quality.

Another feature that you should look for is the coverage area. In order to receive reimbursement, many transfer case warranties will limit you to specific shops, and that can often tie you to a particular geographic area. So if you have problems outside of the coverage area, you’ll be paying for the repairs yourself.

A good nationwide warranty will honor repair costs from a licensed shop, no matter where it’s located. And you want one that will cover both parts and labor. $50/hour is the average cost on transfer case repairs, so make sure your warranty will pay at least that amount.

How Long Does it Take?

Depending on the availability, your reman transfer case can usually be shipped to the repair shop within a few days of your order. Shipping should be free or less than $100. Expect the installation to take 1 to 2 days.

How Long Will it Last?

There is no set time or mileage. We’ve heard of transfer case where they only last 6,000 miles (rare) and others that have lasted over 300,000 miles. Your driving habits and how closely you follow recommended maintenance procedures are the deciding factors. That is why it’s so important to get a good warranty. If I had to give a number, the average would be 150,000 to 200,000 miles.

How to Buy a Remanufactured Transfer Case

1) Buying Locally

When you go to your local repair shop, they’ll order a remanufactured transfer case from a supplier, then mark up the price. So at the end of the day, you’ll be paying 15% to 30% more than the actual cost of the unit.

2) Buying Online or through an Auto Parts store

Buying a reman transfer case through a company online or through Autozone or Advance Auto parts is an option.

Transfer Case Identification – Assembly Number

Your “Assembly Number” on the transfer case helps us to identify the exact model you have. This is typically found towards the REAR of the transfer case (pointing to the rear of the vehicle) on the transfer case itself. Alternatively, they can be looked up by VIN#.

Searchable Transfer Case Assembly Number Table