Engine/Transmission (1994 - 1998) Tranfer Case Problems (Again)

[Todd G]

I have broken snap-rings out of my tranfer case twice in the past. When this happens I get a gear-grinding noise in 2WD that gets worse over time when I apply power. The more power, the worse the noise. After taking it to the dealer and them fixing it twice, I thought I was through.



Now when I put it in 4WD I get the same noise. It doesn't do it in 2WD. It sounds like the gears are not fully engaged and keep popping in and out of 4WD. Not a good sound. I've never dug into the internals of a transfer case but I hear they are pretty simple inside. Anyone else have this problem? What was done to fix it and can I do it myself.



Inquiring minds you know.

 

[1tuffram]

Todd



I had the same problem when in 2wd. In a nut shell the transmission shop found a shim/washer at the rear of one of the shafts which broke. Thus allowing the shaft to slide back a little when power applied and causing much gringing. The guy who rebuild the transfer case put a thicker shim in place of the OEM to help remove some of the "slope". I also had him install any updated or revised parts NV had for this transfer case (1995 truck) since it was apart. I think about the only revised part he could come up with from his suppliers was a new beefier spring for the shift lever.



Anyway I've had no further problems with the exception of a bit of a "bite" when engaging 4wd. The rebuilder said it could be expected since he added the thicker shim and "tightened" up the clearances.



I would find a good transmission shop to do this and forget about DC attempting to fix it. I told the dealer and DC I did not want thier lame brain techs attempting to fix my transfer case. I requested DC supply the parts and I would eat the labor cost to have a shop of my choice do the repairs. DC said no go, which is fine by me because the transmission shop rebuilt it better than new. They did a thourough inspection of all parts and I had them replace anything which looked "iffy" (something DC would never have done)

 

[Cousin Billy]

241 rebuilding

Todd,



I had the same thing happen to my 96 back in May. The snap ring on the main shaft, to the rear of the last bearing, which keeps the mainshaft pulled toward the rear is what breaks. You can easily check this by pulling the tailshaft extension off and the large bearing is right there. I got a rebuild kit, which included all bearings, seals, snap rings and oil pump pickup for about $120 from JB Conversions in Louisana. Also a chain for less than $100.

These are probably the easiest cases to rebuild of any. They sent me a heavier snap ring and a new tail shaft housing with a new bushing and seal installed.

If this is your problem, fix it immediately or you will be buying a new syncronizer ring and more:{ .

You may find the parts elsewhere, this is just where I went.

John at JB Conversions 337-625-2379 www.jbconversions.com.

If I can help otherwise, get in touch with me.



Good Luck!!!!

 

[Todd G]

I decided to not go to the stealer this time and took it upon myself to diagnose the problem. When I took apart the transfer case there was a large piece of metal and a snap ring stuck to the magnet inside

The metal piece was one of 3 "fingers" that are attached to one of the large gears inside. The snap ring is about 4" in diameter. Both seem to be in good shape. It appears the snap ring fell off somehow and let the finger pop out. With only 2 out of 3 fingers left I think this explains my grinding sounds. Everyting in the transfer case seems to be in good condition. There is a little wear in the gear teeth but looks OK.

Now I have to figure out where all the parts go together.

I can't afford to go out and buy the Dodge service manual. I wish there was an exploded diagram on the internet somewhere. Anyone have any suggestions?



Thanks.

 

[Todd G]

The only thing I can't figure out is what the little fingers or pawls are for and how they are attached to the floating gear. I know there are 2 large (4") snap rings that hold them somehow but I can't figure it out. Anyone out there know about the internals of the NP241?

 

[jheath]

Mine, when I put it in 4wd, pulls fine but occasionally binds and then pops real loud and jerks. I figure it is the chain but I am not 100% sure, does that sound about right? My front end wont engage as of lately either. Everything breaks on me at once.