[psmitty95]

Originally Posted by Julian2485

Too much power on that xi of your bro. What oil has metal in the transfer case fluid ?

Yea transfer case fluid. Still driving the car with no issues waiting on the new part. once it's swapped in i'm going to have the Tcase opened up and see what failed

[AtlasM]

I bought the aftermarket worm gear as a preventive maintenance measure and brought it to my mechanic, who is generally very good. He botched the install somehow, so instead he put in a whole brand new transfer case actuator motor at no additional charge. Just went out and got the motor and only told me about it afterward. People make mistakes sometimes and he took care of it. Good guy.

My car has 52k miles on it, and he inspected both my worm gear, and one that came out of a car with 130k miles on it. He said my worm gear still looked fine but the one in the 130k mile car was worn down. But hey, at least now I have a fresh new actuator motor.

[ZGator]

I also bought and installed the aftermarket worm gear - upon inspection of my old gear it was thinning a bit at contact point, but not that bad, however it did not solve the problem - instead of at startup getting the DSC/4x4/Brake errors, it seemed to happen when driving. The puller and gear did work fine - I rather enjoyed it - but I think my issue was with the motor itself - the motor when spun was notchy?

I ended up buying a new actuator motor, they are under $300 now and installed it, so far so good, it's been about a week. I did make sure to run the ISTA-D transfer case adaptation and reclassification of the new resistor before I even started the car after installation.

[k90]

How many miles factory worm gear usually survives?

How about brushes? Have you looked inside the motor? Brushes done at the same time with worm gear?

[k90]

Bump.

Any observations about brush wear level when reconditioning the actuator?