Engine/Transmission (1994 - 1998) 1995 Dodge Transfer Case Problems 241 Hd

[DAngely]

transfer case jumps out of high range makes grinding noise,when going from 2h to 4h makes this same noise. had unit apart no chipped teeth or chain jumping sprockets. problem started a week ago. tried making adjustment on shifting rod,problem stays the same. took transfer case to rebuilder,could`nt find anything wrong with it. replaced trans mount at suggestion of dodge dealer. said possible flexing of drive train. checked motor mounts. had this unit out two times already. when i had unit apart first time,could`nt find any parts of chipped teeth on magnet,just a light film. case looked light brand new inside. is it possible that synchro componets just have enough wear to case problem? shift forks tabs still fit snugly! every place i take this tranfer case to don`t have any clue how to solve this problem. i hope somebody has an idea what`s wrong with unit! thanks DANGELY

 

[HoleshotHolset]

Have you tried driving it without the shift rod connected?

For example: Slap the case in gear and then disconnect the shift rod. That'll pretty much eliminate anything related to the transmission mount or other interference issues tugging on the rod.



If she's popping out with the shift rod disconnected - there's either something wrong with that xfer case or you should really lay off on tugging at Boeing 747's loaded to MGTOW. :-laf



My only experience with a xfer case popping out of 4hi was with Dad's old 208C in a Chevy. After it was rebuilt, it never did that again. The only time it would pop out before it was rebuilt was with really heavy snow plowing.



I've beat the stuffing out of my old NP231 and NEVER had any issues with it. It was pretty much the only thing in that old truck ('91 GMC Sonoma w/4. 3L V6) that I never had an issue with and never had to fix. I went through 2 engines, 1 transmission, 1 rear end, 1 front end...



Beers,



Matt

 

[dieselpowered]

This might be something to check.



This kit is a great do it yourself project and can be retrofitted to your transfer case without removing it from the vehicle. If you have either the NP231, NP241 or NP243 this kit is for you.



Our transfer case save is manufactured by Gillies Products and is designed to replace the factory snap ring on the output shaft that is prone to failure. This common failure generally is not noticeable at first allowing the main shaft to move back and forth eventually causing major damage and expensive repairs to the transfer case. With a broken rear shaft snap ring the main shaft is allowed to move and the oil pump can malfunctions causing improper or no lubrication.

 

[Coalsmoke]

DAngely, how many miles on the transfer case?

 

[DAngely]

about 140,000 miles. up to this point never had trouble with it. thanks for showing interest in this problem. DANGELY.

 

[Coalsmoke]

OK, unless its been abused or is faulty, it shouldn't need a re and re yet. I'm betting that your adjustment is still off. I had that problem before with mine, as it wore it got out of adjustment. I re-adjusted and it got better until a bit later I did a complete rebuild. Undo your linkage, manually put the case in N (might take a hammer and brass punch to know it there), and then adjust. Run it and see if its better. If it is, then check that with the shifter in 2wd that the case is fully in 2wd. If its not fully seated you'll need to look closer at the shift forks or their corresponding collars. There could be two problems here but this where I'd start on this one.

 

[Speck]

95 ram- 2500- stick-11000 miles-trans & transfer case rebuilt
at 85000 (grinding noise in case so had both gone over, cast iron
upgrade on trans ,new clutch) heres the problem-- jumped out of
4high-grinding noise--happened same day 3 or 4 times repositioned shifter good to go---go home in 2h- backing in barn
in 4high jumps out a couple more times.
Next day get about 3 miles from home seemed like trans shifts
into neutral (no gears)
Son gets his 04 2500 ram and pulls me home
Start to pull transfer case ,mounting studs between case and
trans broke off except for 1 (which was a bolt --1 stud short
on install-- what do i look for that caused it .
I am having case gone through since its out (taking it to shop
in daughters 99 2500 ram). any ideas??????
please excuse typing --mechanic by trade
thanks in advance nn- rodeo

 

[Coalsmoke]

What color is your iron transmission housing upgrade, orange or black?

 

[Speck]

Black Housing

 

[Coalsmoke]

Sounds then like you've got a cheaply made after market housing that has the center seal / shaft bore off center in relation to the mounting and as such is putting undo stress on your transfer case. In time it will probably take out the seal between the two units and slowly pump most of the trans fluid into the transfer case, unfortunately some people have not noticed this problem until significant damage to their trans has been done. I would start pulling it apart right now. I have some additional info here somewhere on that problem if need be, I can pass along a link.