I have 1992 4WD with a manual transfer case that is having issues. The floor lever became VERY difficult to move. After messing with it a while, and depending on where the lever ends up, you might get a grinding noise, the truck won't move at all or you are able to get it back to close to normal. I have done a lot of work on this truck over the years, but nothing with the transfer case. Can these be repaired, rebuilt, or do you have to buy a new one? How difficult is the job? Thanks for any comments.

 

you could get one at a local junk yard. or go on craigs list and find some one parting out a truck

 

If you can find the parts and if the pump pin is not worn out you can rebuild these fairly easy. They use a planetary gear for low range so you will not have a bunch of loose gears to contend with, the chain is usually the part that goes bad.