Transfer Case grinding/Slipping

[JLewis]

Hey guys,

Recently I put the truck in 4x4 and the transfer case just made a grinding noise and the truck barely moved. I have rarely used 4x4 since owning the truck and there was no problems with it prior. I'm not sure what transfer case I have (I will have to check) but it's bolted to the NV5600. There is no issue in 2x4, only 4 high and low. Anyone have any ideas? Also my oil pan has rusted a hole through and needs to be replaced. Anyone done this, and can you do it with just unbolting the motor mounts and jacking a bit without having to pull the transmission, etc?

Thanks

2003 Dodge 3500 CC 4x4 Nv5600, Smarty, AFE stage II, Boost fooler

 

[BHanna]

Since you haven't shifted it very much, are you sure you weren't just moving the lever a little slow? I think mine works best when I give it a good quick pull. There's still some feel involved in shifting it though, don't just yank as hard as you can. Try to put a little pressure on it and when you feel it start to move, move it quick. It's even more important going into 4-Low than 4-Hi. If it still grinds, it may be time to take it apart.

 

[JLewis]

Thanks for the reply, but it goes into 4x4 fine. The problem is when you let the clutch out and try to move it grinds like crazy and the truck barely moves. After alittle research on the site I believe the t-case is the NV271, but I have'nt checked the tag yet. This just happened all of a sudden, it was'nt like I was driving in 4x4 and something happened, I just pulled it into 4 wheel on day and it was doing this. Is this a chain driven t-case or gear.

Thanks

 

[DE Jeeper]

I had a slow leak in the tail housing for a while and eventually ran the case dry, this stretched the chain and caused it to skip, not so much grind. You may have a linkage issue and it is not fully going into the gear correclty or you may have a syncro issue. When in 2wd the power runs through the mainshaft and the chain spins free on a gear on the mainshaft. I pulled the case and rebuilt it for about $300. Check the fluid and report back to us.



On the oil pan you should just be able to pull the bolts and drop the pan without pulling anything off the transmission.



Aaron

 

[sag2]

The pan is not as easy as removing the bolts and it falls out. You need to get the engine up as high as possible. Make sure the hood is up and watch for stretched hoses, wires and cables. Also the fan may need to "sneak" by the back of the shroud, or pull the fan. You need to lift it from the balancer so be careful. The pick up tube needs to be unbolted once you have the pan partially down. It can be done, just pay attention, be careful, and go as high as possible without breaking anything. Block it up for safety, as you have 1000+lbs in the air with you and your hands under it.

 

[BHanna]

It sounds like you're shifting into 4wd while stopped? That could be part of the problem. You may not be able to get it all the way in gear like that. Try shifting into 4-hi on the fly (below 50 mph). When going into 4-lo, have the truck barely rolling (~2 mph), trans in neutral and then put a little pressure on the lever and when it starts to move, move it quickly all the way forward (at least that's the direction on mine).

 

[JLewis]

Confirmed that the t-case is the 271 D. Fluid is full and it is not a linkage issue. It is definately in 4x4 when I try to move the truck, and it does kind of sound like a chain slipping around a gear. It's just wierd that this would happen without any warning. Could the chain have broken? Any other ideas?

Thanks

 

[JApol]

I had a problem similair to Jeeper and when I drained the fluid from the case it was heavily contaminated with metal filings. The t-case had to be replaced.