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XHD Pump Rub Repair Kit with Pump | 2001-2007

Merchant Automotive

$554.64
SKU:
10774
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The Merchant Automotive Transfer Case Pump Upgrade and Repair Kit with pump is an all-inclusive kit for repairing a 261XHD or 263XHD transfer case that needs a new rear case because of pump rub. It fits 2001-2007 Chevy Silverado and GMC Sierra 2500HD and 3500HD trucks with the LB7, LLY and LBZ 6.6L Duramax diesel, as well as 8.1L gas trucks equipped with the Allison transmission. It includes a new OEM magnesium rear housing, a new pump with our billet pump housing, all of the seals and snap rings, snap ring pliers, and our magnetic drain plug kit and fluid.

Pump rub is a prevalent problem on 2001 to early 2007 GM transfer cases, and our pump upgrade is one of the most important upgrades you can make to these trucks. If your case has not failed yet, our basic Transfer Case Pump Upgrade Kit can be installed as preventative maintenance. If your rear housing has already been damaged by pump rub, this kit has all the parts needed for a repair that requires a new rear case half, and it prevents pump rub from happening again.

When properly installed, this kit is backed by a Merchant Automotive Limited Lifetime Warranty against pump rub failure.

Features

  • All-inclusive kit to repair pump rub damage and prevent it from coming back
  • Direct replacement, stronger than factory
  • New OE-style magnesium rear transfer case housing
  • Merchant Automotive billet T-6061 aluminum CNC-machined pump housing
  • New 49 spline pump assembly included
  • Includes all seals, snap ring, grommet and 9" snap ring pliers
  • Magnetic drain plug kit and 2 quarts of performance transfer case fluid
  • Limited lifetime warranty against pump rub

What's Included

What Is Pump Rub?

Pump rub is a common gear pump failure in GM transfer cases from 1998 to early 2007. The gear pump forces oil to the planetary and the drive sprocket sleeve. Because the pump is driven by the mainshaft, the pump housing floats in the rear housing and is held in place by tabs that sit in pockets in the rear housing. The aluminum pump housing is harder than the magnesium rear housing, so over time it wears into the rear housing until it wears a hole and starts to leak. The leak usually happens while driving, not while parked, so it often goes unnoticed. These transfer cases have no low fluid warning, so by the time the problem is found, the damage is usually done. GM installed a spring steel anti-rattle clip to prevent this wear, but the clip often breaks and stops working.

Installing this kit repairs the damage and prevents pump rub from happening again.

Pump Rub Warranty

This kit comes with a Merchant Automotive Limited Lifetime Warranty against pump rub. If you have this kit installed and the pump wears a hole in the new rear housing, we will replace the transfer case. This warranty applies only to installations with a new rear housing, which this kit includes.

Before You Order

Note: This kit does not include internal transfer case parts. A transfer case that has been run without fluid may have additional internal damage that cannot be seen until it is taken apart. Additional parts may be needed.

Installation Tips

  • Inspect the internal parts for heat damage or wear while the case is apart, especially if it ran low on fluid.
  • Discard the factory anti-rattle clip. The billet pump housing is machined to work without it.
  • Make sure the rear output bearing snap ring is fully seated before closing the case.
  • Use the included RTV silicone as directed during reassembly.
  • Fill with the included 2 quarts of fluid before driving, then check for leaks.

Installation Resources

Related Parts

Frequently Asked Questions

My transfer case has not failed yet. Do I need this kit?
No. If your rear housing is not damaged, our basic Transfer Case Pump Upgrade Kit can be installed as preventative maintenance. This kit is for cases that need a new rear housing.

Do I reuse the factory anti-rattle clip?
No. Discard the OEM anti-rattle clip. Our pump housing is machined to work without it.

What other parts will I need?
This kit does not include internal parts. It is hard to know what damage was done until the case is taken apart. In most cases, a transfer case that did not run dry can be repaired with this kit. Refill the case with the included fluid and replace the drain and fill plugs with the included magnetic plug kit, since the factory plugs are often rounded off.

After installing the kit, I hear a grinding noise at low speed. What causes it?
This is usually caused by the rear output bearing snap ring not being fully seated. Check that the snap ring is fully seated in its groove.

After installing the kit, I have a speed sensor correlation code. What causes it?
This is also usually caused by the rear output bearing snap ring not being fully seated. Check that the snap ring is fully seated in its groove.

Does it fit both the 261XHD and the 263XHD?
Yes. It fits both the manual shift 261XHD and the electronic shift 263XHD.

Does it fit 8.1L gas trucks?
Yes. It fits 2001-2007 8.1L gas trucks equipped with the Allison transmission and the 261XHD or 263XHD transfer case.

What is the difference between this kit and the other repair kits?
This version adds a new 49 spline pump assembly with our billet pump housing. It does not include the rear output seal driver; the version with both is the most complete kit.

For warranty information or to submit a claim, see our Warranty Form.

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