Transfer Case Lever

[Archive]

I saw this post a while back about a fix for the lever rattling while driving yet a search brought up nothing. Does anyone have the thread or remember how to fix this? I have a NP 205.

Thanks
Matt

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90 W250, 5-speed, 3. 54 gears, 16 cm2 housing, tach, pyro, and boost gauges.

 

[Archive]

I remember responding to that thread and there was even a segment mentioning it in the last issue of TDR. I couldn't find it when I did a search either. I even sorted through all the first gen threads and for some reason they only go back as far as March. It seems that all the threads from before March that were not put in the archives are gone. Maybe it has something to do with when the site crashed about then. I lost my user name and all posts I'd done since november of '99.
Anyway, it seems that in the thread, one guy said he had used a rubber washer that was supplied by a Dodge dealer. Something about using a C-clamp to hold the spring while installing the washer.
Me, I've still got my water jug hanging on the lever. #ad


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'93 W250, LE, CC, 4x4, 5spd. , Cummins, K&N, 16cm turbo, High flow Bosch injectors, Professionaly rebuilt and calibrated pump, straight exhaust, Lund visor w/lights, 5th wheel, Gooseneck, H. D. rear hitch, Aluminum everything.

 

[Archive]

Lt my 92 had the vibrating shift lever also. I fixed it by adding an extra spring washer on each end of the shift rod. The pn is 869770.
Gene
92 350 4x4

 

[Archive]

Hey Lt!

I was the member that posted the original thread back in December 4 1999.

I haven't bothered to do a search for it but I do have a copy of it in "Dewey Decimal System" of Keeno's large 3 ring binder. If you would like the tread I'll fax it to you if you email me a Fax number. For the rest of us here's a recap.

"BV" said he has used Heavy Duty Grease applied to gate mechanism w/ good results. This didn't work for me.

"GeneH" purchased new spring washers as mentioned in this thread. I too have purchased 2 spring washers but have not installed them to date. I'm in question whether they are robust enough to move the lever to the right to fix my problem.

"KAD" was the one that mentioned the rubber washers but could not supply the part numbers for the washers. He also mentioned that the washers were installed using vise grips to compress the shaft assembly. I haven't tried to purchase the washers or assemble them onto the shift mechanism.

As you can tell from this post I have not corrected this problem for myself. I'm still riding around with my Condura Courier Bag dangling form the shift lever pulling it to the right to correct the problem. I haven't been over to the TSB side of the sight lately but I can almost convince myself I saw a TSB for this problem that might have the part number for those illusive rubber washers.

Hope this helps a bit... ... . Keeno



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1992 W250 5spd. 3. 54 gears, LSD, JRE enhanced VE Injector Pump, BD High Output Injectors, Banks "Stinger Plus" consisting of a 14cm2 wastegated housing, 3 1/2" JRE modified exhaust/muffler, pyro/boost gages, K&N, Skyjacker 2 1/2" front suspension lift to clear 305/70R/16 Goodyear MT's, Mag-Hytec, Amsoil

 

[Archive]

Hey Lt, I had the rattle problem several years ago. I went to the Dodge dealer in Amarillo, Texas and explained my problem. He sold me a rubber washer that was to be inserted between the shift fork spring and the input shaft to the transfer case. The stock assembly was held in place by a cotter pin. After inserting the washer, I could not insert the cotter pin without using a C-clamp to compress the spring. After some minor explatives my rattle was gone. Hope this helps.

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Stock '91 sc W250, 5sp, 3. 54's, 235/85's,250k+.

 

[Archive]

Thanks for the info. Next question would be does anyone else have the same transfer case (NP 205) as I do. I've noticed that everyone else's trucks are 92's and 93's. I'm just wondering because the linkage is different on different cases so would the same solution work.

Matt

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90 W250, 5-speed, 3. 54 gears, 16 cm2 housing, tach, pyro, and boost gauges.

 

[Archive]

Hey LT & KAD!

Lt, the real beauty of our First Generation 4X4 trucks is that they all came with the NP205 cast iron - gear driven transfer cases (you don't need no stinkin' chain)! The NP205 has always been considered to be virtually BOMB-proof and has been considered desirable for many applications in the 4X4 world! Luck us... .

KAD, I might be asking a HUGE favor here, but might it be possible to check with your most knowledgeable parts person and get us a part number for the fix? I'm sure we would all be eternally grateful!

Thanks..... Keeno

 

[Archive]

Keeno,
When I was looking to replace my Powerstroke with a Dodge, one of the 92's had a NP 241 transfer case. The lever was not a straight 'gate' like the NP 205. But it also helps to know that probably most trucks are like mine and this will fix my rattle.

Thanks
Matt


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90 W250, 5-speed, 3. 54 gears, 16 cm2 housing, tach, pyro, and boost gauges.

 

[Archive]

Hey Lt!

I could be wrong but to my knowledge the First Gen's were NP205's. Maybe some of the other members can check the service manual and confirm this for us. Sorry if I supplied bogus info on the NP205.

Look on the brighter side you dodged the bullet on a 'die cast aluminum cased chain driven transfer case' (NP241) for a bit shift lever rattle!

Can someone clear this up for us..... Keeno

 

[Archive]

My 92 has the NP205 transfer case.

According to the 92 Service Manual the NP205 is a heavy duty unit and is used in W250/350 models.

However, it also shows the NP241 transfer case but does not show in what models it is used (I didn't see anything).

 

[Archive]

The 1st Gen trucks have the New Process 205 transfer case.
A very few '93's have been built with the New Process 241 (chain driven) tran. case
All '94 and up have the NP (later to be New Venture) 241 T. C.
Yep... The 205 is the stoutest of all.
Hey KEENO: I hear there is a '92 POWERHOUSE 'round your parts with a non rattling 205...
Smooth running Folks!

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'98 2500, Cummins 12v, 5spd, 4wd, 3. 55, GOT DIESEL?

 

[Archive]

Hey Old School!

Great to hear from you! Thanks for helping us out with a bit of clarity on the NP205's.

Yeah, I've seen this truck around quite a bit lately. It's always clean, freshly waxed (the old fashion way) with large shiny black 36" tires. I'm afraid she's going rub the paint off the ole girl washing her so much. I understand the owner's taking her in for some aftermarket air conditioning next week, not cheap @ $1357. 00 - $1450. 00 so far.

My plan for transfer case rattle? Sneak in one night when the owner is sleeping and swap out shift levers and mechanisms! I don't want to be bother with little rubber washers.

Keeno

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1992 W250 5spd. 3. 54 gears, LSD, JRE enhanced VE Injector Pump, BD High Output Injectors, Banks "Stinger Plus" consisting of a 14cm2 wastegated housing, 3 1/2" JRE modified exhaust/muffler, pyro/boost gages, K&N, Skyjacker 2 1/2" front suspension lift to clear 305/70R/16 Goodyear MT's, Mag-Hytec, Amsoil

 

[Archive]

Pretty sneaky! At least you won't have to crawl under the truck. Probably can do it sitting up.
I miss the sound and the fury. Workin' on it.
Best to the "cool" gal.

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'98 2500, Cummins 12v, 5spd, 4wd, 3. 55, GOT DIESEL?

 

[Archive]

Hey all, regarding that pesky part number... I'll get to work on it (probably shouldn't have opened my mouth without it... sincere apologies). The Dodge dealership I got the part from is in Amarillo, Texas off of IH-27 (I've since moved). I'll post as soon as I get it.

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Stock '91 sc W250, 5sp, 3. 54's, 235/85's,250k+.

 

[Archive]

Sorry for the extended hyatus... too much work and not enough play...
After some research thru Dodge (and their "expert" parts people... a little sarcasm here) I think I've found the part number for that rubber washer I was talking about in earlier posts. It's official name is "shift lever grommet" with Dodge part #3467791, cost $3. 35. Best of luck to all.
kad

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Stock '91 sc W250, 5sp, 3. 54's, 235/85's,250k+.

[This message has been edited by KAD (edited 06-16-2000). ]

 

[Archive]

Hey KAD! Way to go Man!

Hopefully I'm speaking for everyone with a "Transfer Case Lever Buzz", but thanks a ton for taking the time to track down that part #. My local dealer just stared at me dumb founded when I tried to explain the fix and these rubber washers.

KAD, You rule! Have a great weekend..... Keeno

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1992 W250 5spd. 3. 54 gears, LSD, JRE enhanced VE Injector Pump, BD High Output Injectors, Banks "Stinger Plus" consisting of a 14cm2 wastegated housing, 3 1/2" JRE modified exhaust/muffler, pyro/boost gages, K&N, Skyjacker 2 1/2" front suspension lift to clear 305/70R/16 Goodyear MT's, Mag-Hytec, Amsoil