2nd Gen Non-Engine/Transmission 5 Speed Transmission Up Grade

[JWalsh]

I plan on adding some power goodies to my 94, 98000 miles but I want strengthen my 5 speed and 241 transfer case . I currently have the Dodge fix on my out put shaft but I don't trust it. I am going to put in the fully splined output shaft, new bearings and synchros. I notice in the TDR that Haisley Machine and Repair advertises a 1-3/8" input shaft. I was wondering if anyone out there has any experience with these and how much they cost. I tried to contact them yesterday but they must be closed for the holidays. I was also wondering if the 241 transfer case can be made into a 241 Heavy Duty by changing certain parts or if I need to replace it entirely. I see all these other posts with added horse power and torque on the TDR, what was done to the drive train to handle it?

 

[WKener]

I have no experience with Haisley's, but as for the t-case I wouldn't worry too much about it's overall integrity. If I remember correctly, the 241HD uses a bigger drive chain, has an extra bearing on the mainshaft and has a slightly stronger case design as compared to your 241D.

After you upgrade clutches (I recommend Southbend Clutch), install the fully splined main shaft and replace synchros/bearings in the transmission, I would think you are good to go. The transfer case is typically up to the task of handling the extra load a hopped up Cummins makes... Others can shed a little more light on this I am sure, but I hope this helps.



Wes