Transfer case explosion

[WorstLuckEver]

So, I was driving down the road in 2 Hi in my ‘02 2500, 5.9 Cummins, nv4500, 70 mph, heard a huge clunk from under my feet. To make a long story short, my transfer case housing is now in a million pieces and the front cv shaft was found laying on top of the skid plate.

Since this is my only vehicle, I unbolted the front shaft and am driving it about 10 miles to work daily. However, I live in Minnesota and the snow is coming and I will need 4WD soon.

I can’t find a used NP241DHD and remans are about $1000. Too rich for my blood. A buddy offered to give me a 241C out of a 1 ton Chevy in his grove. The price is right, but can I make it fit without losing the rest of my hair?

My other option is to buy a new housing and hopefully the guts in the original are good enough to reuse.

Did I mention that my wife is fuming mad over the almost $15k that I have put into repairs in the last 5 years and I haven’t told her about this yet.

 

[NIsaacs]

You need to stop driving it or you will have even "WorstLuckEver" The dry remains of the t-case will soon seize up solid, as in no go at all.

 

[Ozymandias]

Check craigslist in your area, there should be some TCs on it, it is not a rare piece.

 

[mweiman]

I think trying to piece that back together with a new housing would be a bad idea. May end up with as much as a reman in it by the time you were done. Just my opinion. Rockauto has reman zumbrota for $935. I think zumbrota is in Minnesota so shipping might be reasonable.

 

[Signal73]

Have you ever checked the fluid levels

 

[Timd32]

Did I mention that my wife is fuming mad over the almost $15k that I have put into repairs in the last 5 years and I haven’t told her about this yet.

What other vehicle can you get for $250 a month. It seems like a lot of money but less expensive then a new truck.

You can also check out www.car-part.com and find a local wrecking yard with some decent inventory.

 

[KATOOM]

It looks like the chain jumped the sprocket and bunched up. That will cause the case to explode as the chain pushes out. I'm going to make the guess that your '02 did not have the CAD front axle because if it did then this could never have happened... Thats important to know too because the CAD and non-CAD transfer cases are different due to the CAD disengagement in 2 hi. If you can find a junkyard replacement then that would definitely be the cheapest but I'm not sure there's too many of these trucks in the yards.

 

[EricViviano]

Same exact thing happened to a friend down the road a few months back. 99 Reg cab Nv4500. Transfer case grenaded.

 

[mfurrh55]

There is a few for sale on ebay