Engine/Transmission (1998.5 - 2002) Pulled my non-functional X-fer case... need help

[Cummins Thunder]

A few months back I was pulling (well... trying to :{ ) out a Power Wagon, and I started to hear a grinding. Well, I noticed I was also losing my front wheel drive. So I unhooked and hauled *** thru some giant ruts, and two ditches to avoid being stranded. Well a few months go by and I blow apart my input shaft . I figured I might as well fix the transfer case while I have it all out. So today I pulled apart the case and found... NOTHING broke



It seems that the shifter fork is not pushing drum thingy far enough over drum thingy number 2, and it has rounded off the edges of the teeth.



Its hopeless for me to try and describe it with words. So check the pics below.

What do I need to do to fix this? This is the first X-fer case I have ever messed with.

 

[Scrappy]

that looks about normal, the teeth are chamfered to help it to go into gear. as I wouldn't realy worry about the parts in the pictures. How long has it been sincethat magnet was cleaned? The magnet doesn't look like it has an excessive amount of metal on it. If there are chunks on it then you have to worry.

 

[Cummins Thunder]

I agree that the edges look about normal. But the two drums don't engage eachother far enough. So all I get is a nasty grinding noise of the edge of the teeth on the two drums hitting eachother when I engage the front axle.

It seems tat they are just "out of adjustment" but I cant find a way to adjust the engagement of the drums.



At the track I have always had a nasty "POP POP POP" upon launch, now I know what was going on



I am stumped



BTW... The magnet has never been cleaned.

 

[Cummins Thunder]

Guess I am the only one to have this problem...

 

[Scrappy]

are the shift forks and rails worn or damaged? is it something in the transfercase not letting the drums completely engage or could it be the shift linkage?

 

[Nate]

You see those whitish pieces of plastic on the paper towel? Those look to me to be shifter fork pads.



Should be 3 on each fork, though I haven't torn apart a 241, so it might be a little different compared to the smaller Jeep cases.



Also check for any broken snap rings, which could give you in/out play on the mainshaft.

 

[horned Toad]

Are you sure the problem is in the t-case and not the two piece front axle, a vacuum leak could be keeping the front collar on the axles from fully engaging

 

[Makensmoke]

I agree on the shifter fork pads. My pads were gone and ground the forks down so I noticed alot of metal in my oil change. I found alot of plastic inside the case when I explored. I did not notice grinding or missing but I don't think I play as hard as you do. Those pads would however limit how much the gears are "thrown".

I would also agree that due to lack of metal on that magnet and the fresh looking teeth I would look into the front axle for something wrong.

 

[Extreme1]

The fork pads and shifter adjustment are all part of getting the collar to slide to the right spot. I had to replace a few parts a long time ago, it's been fine since.

 

[Cummins Thunder]

My truck has the solid front end. No axle disconnect, otherwise known as "CAD".



I think my problem is kind of a chain reaction, that stems from the shifter linkage being out of adjustment.



The teeth on the drums are a bit rounded off for my liking. So I am replacing them. Looks like its gonna cost me about ~$250 oh well...



Till all this mess gets fixed im still driving a V-6 Dodge :{ :{