Initially, I suspected an engine-related issue, as the noise appeared to come from the front of the vehicle. After further investigation, however, it became clear that the transfer case (TC) was the real culprit.
Before reaching that conclusion, I even considered the gearbox as a possible cause. To rule that out, I replaced the gearbox oil and filter twice — without any improvement.
Confirming the Transfer Case Failure
The real confirmation came when I drained the oil from the transfer case.
The condition of the oil immediately raised red flags:
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The oil looked heavily contaminated
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Metal particles were present
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The small internal mesh filter was completely clogged
At that point, it was obvious that the transfer case was the source of the problem.
Finding a Replacement Transfer Case
Fortunately, I managed to find a second-hand transfer case. That did require a four-hour drive to pick it up and bring it home — but sometimes that’s the price you pay for the right part.
Of course, there was still some doubt in the back of my mind:
What if I install this unit and it turns out to be just as bad?
To avoid that risk, I sent the replacement transfer case to a specialist company capable of inspecting its internal condition.
Good News at Last
Yesterday, I received the verdict — and it couldn’t have been better.
The transfer case was described as “brand new on the inside”, showing no signs of wear and requiring no rebuild or additional work.
That was a huge relief.
What’s Next
With a confirmed good replacement unit ready to go, the next step is straightforward:
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Remove the old, failed transfer case
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Install the replacement unit
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Finally get the P38 back on the road
After a string of setbacks, it’s great to have something go smoothly for once.
More updates soon 👊
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| P38 Borg Wagner transfer case |
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