Engine/Transmission (1994 - 1998) Broken transfer case

[Glen Pratt]

Last snow storm I was driving home from work in 4 wheel drive. I was doing about 45 MPH when I heard a pop. Then my transfer case started making noise. I popped it out of 4 wheel drive and the noise stopped. I creeped home in 2 wheel drive. When I got out of the truck I smelled burnt transmission fluid. I checked the transmission fluid and it was fine. I'm thinking that I broke the rear output shaft c-clip, but from what I read here if that's the problem, putting the transfer case in 4 wheel drive the noise should stop. I have the opposite. I bought the Gilley's Transfer Case Saver but never got around to installing it. If this is my problem I'll be kicking myself in the ass. Correct me if I'm wrong, if the c-clip breaks and the output shaft moves, doesn't this stop the pump from turning? This would explain my burnt fluid smell. I haven't really looked at it as the temperature has been pretty cold. I'm debating what to do. It's a 241LD case. I'm thinking of pulling the case, getting a rebuild kit, and upgrading the chain. Any help would be greatly appreciated. Thanks, -Glen

 

[SBrandon]

Glen, after the pop, did it grind on ecelleration and braking?

 

[Glen Pratt]

Yes, that's exactly what it was doing. It stopped when I took it out of 4 wheel drive. Any ideas? -Glen

 

[SBrandon]

Yes, I have the same exact problem, the only differance I never smelled burnt trans fluid until my transmission burned out. I have rebuild my t-case twice now, first time repaced everything but the range fork and the second time I replaced the range fork and the snap rings. The back snap ring which you have a case saver for on my truck was not broke but rather looked like it was not serving its pupose. (hard to explain). After this it worked excellent for about 50 miles then another problem arose, this is just my two cents. My suggestion for fixing is to contact Mid West Transmission in Zumbrota, MN. They can sell you parts to do it yourself or they will fix it for you. Best prices i have found.

 

[willyslover]

http://www.transfercases.com/

very good prices and probably parts also

 

[Desperado]

I just replaced my T-case with a new one from Transfer Case Express. The dealer wanted $900. 00 just for parts to rebuild my old one and another $400. 00 to R&R and rebuild, Transfer Case Express wanted $995. 00 for a brad new one no core no S&H. The new one work better then the old one did even when it was new, and they are good people to work with you will have to give them your VIN# and tell them it is a either a241 DLD or 241 DHD, they do have rebuilt units for about $65. 00 plus core.



Not Affiliated with this vendor just a satisfies customer.

 

[Glen Pratt]

Thanks for info. -Glen

 

[Glen Pratt]

TTT

 

[CDyksman]

The c-clip on my '96 broke and the chain moved and actually took out the pump, which broke the chain, which then shattered the drop out gear. Needed whole new case.

 

[Glen Pratt]

Thanks, I'm going to check it out tomorrow. I think I'll be dialing up Transfer Case Express and upgrade to a NV241HD case. New 241HD case on sale for $995. 00 no core and free shipping for the month of February. Thanks for the help. -Glen

 

[Todd G]

I'm thinkng of upgrading my transfer case also. Mine makes loud banging noises when in 4wd. Will the 241hd bolt right up with no mods or do you have to shorten and lengthen the driveshafts?

 

[Glen Pratt]

I'm not sure. I'll find out when I call on Monday. They ask for your trucks Vin#. I would think it would being that both cases were offered in these trucks. If not they have new 241LD cases for the same price. -Glen

 

[willyslover]

guys the front of the drive shaft slip yoke will need a mod on the case change. . the spline size is larrger on the HD case... two options are to have a new front yoke slidder installed with a u joint or find a donor from a wrecker... [I think the shaft needed a bit O trim also as the HD unit is a bit longer. . I have never done this 'cause I have always had the HD but my old case went to Brandon Fenley [TDR member] who did the change out and also used the rear end yoke for the u jount off my donor rig and upgraded the shaft with larger u joint while at it

 

[Texas Diesel]

pm me your email and I will send you a file that expalins what fails, has pictures and tells how to fix it properly



The HD case has a PTO cover the DLD (whatever) doesnt have a PTO cover, only the HD's have the circlip in the extension housing.

 

[Glen Pratt]

Tejas Deezul, I pm'd you my e-mail. Thanks for the info. I kind of figured the spline shafts were different sizes. -Glen

 

[Glen Pratt]

Well I finally got around to checking out my truck. It turns out the transfer case is not the problem. The pinion bearing and seal went on the front axle. I had an ARB Air Locker installed in my front axle a little over a year ago. I spoke with the shop that installed it and he will check it out next week. Appreciate everyones help. -Glen