PROJECT LML

owner manual suggests the use of standard automatic transmission fluid, Merchant Automotive has done some extensive research and testing and developed a new fluid that can help reduce wear and chatter within the transfer case. Their transfer case fluid comes in a 2-quart jug, just the amount you’ll need, and has been specially formulated to eliminate some of the clunks you’ll hear under normal driving by lubricating and cushioning the internals better than ATF can.

Last, looking at the longevity side of this project, we wanted to prevent the common problem of cracked transmission tail housings due to the weight of the transfer case hanging off the back without additional cross members for support. In the case of a failed U-joint or an imbalance in the driveline, enough vibration in the drivetrain has been known to lead to cracked transmission cases, which are expensive to repair. Merchant Automotive engineered their Transfer Case Brace to be bolted in directly above the transfer case to help distribute some of its weight to the transmission’s center section and add some rigidity to the drivetrain. The brace can be installed without removing the transmission or transfer case and requires just basic of hand tools and maybe 30 minutes of your time.

While this was more of a general maintenance part of the project build, it’ll be crucial to the overall usability and longevity of the truck with improved transmission performance and without breaking our piggy bank. The truck still drives just as nice as it ever did, but increased line pressure will help keep the clutches from slipping and will be more efficient under every driving condition, whether we’re towing or hot rodding through town.

In Part Five we’ll finally get to dress this guy up for the ball with a better stance from a Dmaxstore.com Stage 3 Leveling Kit that includes new upper control arms, ball joints, torsion keys and Bilstein shocks. We just mounted and balanced a new set of dancing shoes from Mickey Thompson as well that should really toughen up the looks and on/off-road performance. Since the truck will be used for heavy towing through the summer months, an extended range Titan midship fuel tank and Ez-lock turnover gooseneck hitch from Curt Manufacturing needs installed too, so be sure to check in each month to see where this build takes us next.

 On the four-wheel-drive GM trucks, the transfer case basically just hangs off the case of the Allison transmission and excessive driveline vibration from a bad U-joint or out-of-balance driveshaft has been known to crack that case, leading to...

 With the transmission all back together and refilled with fresh transmission fluid it was time to move back to the transfer case. A truck’s transfer case is probably one of the most overlooked maintenance items for any owner. They only hold 2 quarts...

 While most places will use a standard automatic transmission fluid inside the transfer case, Merchant Automotive’s specially formulated transfer case oil can reduce wear and improve performance. The special fluid can lubricate internal parts while...

 While it’s not a huge difference sitting side by side, the stock transmission pan next to the severe duty deep transmission pan (OEM Allison piece) will increase fluid capacity by 3 quarts. The supplied deep sump filter also uses an updated design...

 The MA transfer case support is simple to install and will require you to just remove bolts at the top rear of the transmission and two at the top of the transfer case. You just slide the brace into place, being sure not to pinch any wiring or the...