Engine/Transmission (1998.5 - 2002) Transfer case pops out of gear while towing

[JPulliam]

Today I brought a load of gravel and a tractor back from my parents place. While driving the transfer case kept popping into neutral. My weight ticket said I weighed about 19K gross. Is that the problem, or is there something else I should look into? It did this once before unloaded.

 

[BDaugherty]

First thing I would do is check the adjustment and make sure that the linkage isn't hitting anything when the driveline torques. After that pull the Tcase apart and pay close attention to the shift forks and thrust washers.

 

[cmills]

same thing

A couple years ago I had the same problem with mine. Mine would only do it in 2wd, so I took the front driveshaft out and drove it with the transfer case in 4wd. I wish I could tell you what the actual problem was, but I can't remember exactly what was wrong. (Stepbrother did the work) I do know nothing was "Broke" it was just wore out. The truck had around 250,000 miles on it and I did change the fluid quite often, but it had also done a lot of snow plowing. I guess all things eventually wear out no matter how good of maintenance you perform. By the way how many miles do you have on the truck?


Cory

 

[JPulliam]

The truck has about 182000 on it, and I got it with 140000. I rarely use 4wd, and I don't just beat on it. I checked the linkage yesterday, and it does not appear to be binding or hitting anything. It did this once before when I was unloaded flooring it up a hill. Just popped into neutral and I lost all forward momentum. I did some tests coming home last night. I have a 2 wheel low switch, and I used it with the transfer case in 4 hi. It still popped between gears but did not do it as bad or as often. It only pops out when the transmission is in 4th. The whole time I was in 5th it drove normal, but as soon as I would go to fourth it would pop out. I could not hold the transfer case in gear, no matter what I did to the stick, so that makes me think something is bent or deflecting inside. Why does it only do it in 4th, though. Hope I don't have a transmission and transfer case problem.

 

[wcjp]

Not sure about the Dodge. On a Jeep, this could be a worn out TC or bad motor mount and/or bad transmission mount.

 

[JPulliam]

What is a TC? Torque converter? The transmission mount was solid as can be when I put a clutch in it last summer. Motor mounts, not so sure. I have not checked them.

 

[JPulliam]

No more ideas, or external checks? What should I look for when the case is apart? How do I tell if something is "bad" or worn out?

 

[JMcKee]

Had the same thing happen to my 02 and my buddies 99, replace the shift fork in the transfer case, there are plastic inserts on the fork tips which wear and cause some play, also while you have it apart increase the spring tension on the shifter detent approximately 0. 25" (just make a spacer to put behind it to increase the tension but not too much you cant shift the t case). Thats what i did to my truck and it worked, no longer pops out of gear.

 

[RLHannink]

Had the same thing, t-case popping outta high range into neutral. Caused by a severely worn range fork (due to running it out of oil). If the problem doesn't occur when you pull it into low, then the fork might only be worn from the front, and still will have enough metal to hold it into low range. New fork = problem solved, not that hard to do.

 

[JPulliam]

So, I need a range fork for my NP241 DHD case. Just like this one? P/N ALLT17543
NP241 Transfer Case Parts Illustration and parts list, you save money! - Drivetrain.com

Do I need the pads, too? P/N K201300

Is there anything else I should replace while I am in there?

 

[JPulliam]

While researching this problem I came upon an interesting idea. The input shaft on the 5 speed, like mine, as 4'th gear on it. This problem ONLY happens in 4'th gear. I wonder if for some reason the input shaft retainer is loose, and causing the TRANS to pop out of gear, and that is somehow affecting the T Case. I pulled the PTO cover off of the case to check the gears and shift forks out. No metal in the fluid, and I did not see any damage. The plastic pads on the range fork did not appear to be worn. Let me know what you guys think about this scenario.

 

[JPulliam]

I talked to a couple of transmission shops today, and they both said the same thing. Range fork is worn out/bent. On one hand I want to just pull it apart and replace the range fork, but on the other I don't want to miss something else worn out and pull the case again. Is it difficult to replace the range fork, and do I need any special tools to do this?

 

[Dieseldemon]

No and No The range fork is the alu one also replace thr plastic pads on the steel fork National Drive Train has a pad kit with all the plastic pads in it they are in chicago they also have the forks. 800 507 4327 Talk to Kevin as most of the others are to lazy to look it up. Hope this helps

 

[JPulliam]

I have a transfer case saver ordered from quad4x4, and as soon as I can save a few more pennies I am gonna pull it and have it rebuilt. Anything I should have them do, or certain parts I should go ahead and get?

 

[JPulliam]

I pulled and disassembled the case last night. The pads on the mode fork were worn, and one was cracked, the sliding clutch and stop ring have some damage from the gear grinding under load, the input shaft bearing came out in pieces. The cage that holds the ball bearings is GONE! Well, not gone, but attached to the magnet in the form of a furry metal mess. Nothing else seemed damaged, but I am going to replace the thrust washers in the planetary just in case. The other bearings look good. All you need to disassemble this case is a set of sockets and a good pair of snap ring pliers. It just comes right apart.

 

[JPulliam]

So far, so good! I have not had any more problems out of this t-case. It shifts better than ever, and all for $285 in parts.

 

[Cummins724]

I had a thread up last week on another site that was exactly the same as this one. I replaced my transfer case input bearing & noticed that the snap ring was missing from the shift synchronizer hub. I believe the balls fell out of the front bearing & got into the hub & broke the snap ring. I replaced that while I was in there & put it all back together. I was pulling 18k# trailer & went down a mountain. My truck kicked out of 2 wheel drive while decending [in 4th gear]. On my way back to my shop, I lost 5th gear completely [5th gear nut. Luckily I have a full warranty on my transmission & it is at the transmission shop right now. I'll let you know what was wrong with the T-case.

 

[JPulliam]

Good stuff to know. Nothing big ever breaks when you are driving through a school zone at 15 mph, you know!

 

[Cummins724]

Good stuff to know. Nothing big ever breaks when you are driving through a school zone at 15 mph, you know!

Tell me about it. :-laf

 

[Cummins724]

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Verdict is in. I broke all of the teeth out of the 5th gear clutch gear #30 in pic. 5th gear nut was fine. transmission shop only charged me $50. for the new part installed.