2nd Gen Non-Engine/Transmission Transfer case questions

[mweiman]

I have a few questions that I didn't have any luck searching for. I have a customer with 1995 3500 C&C 4x4. I didn't look at the tag or for a pto cover, But assume it is a 241HD. The transfer case looks to be leaking where the case halves bolt together. The bad part is that the truck may sit for a few months at a time and then get run hard without getting the fluid checked. How bad of a job is it to split the case and also maybe replace the chain while I am in there(and other preventative maintenance, truck has 117,000 miles). It doesn't look like it would take much to remove and replace the case, but I haven't had one apart in several years. Thanks for any help.

Matt

 

[JMcCoy]

I believe it is a 241DHD. The case comes right out. Just disconnect the drive shafts, linkages, vacuum lines (if still present), and unbolt it. Unless it has been beat on, in 4wd, I wouldn't worry about the chain. I don't believe you have to open the case to replace the front deal. I would do the rear seal as well. I would also use a good synthetic fluid. Tell him to at least check the fluid if he goes through high water. Good luck.

 

[mweiman]

The case is leaking where the case halves bolt together in the middle, the seals look ok, I would probably change them anyway if I had it apart. I don't believe the 4wd gets locked in much other than in the winter, it has a dump bed on it and probably doesn't get offroad much.

 

[HCannon]

Had the same type leak and it turn out to be a crack in the housing between the trans. and the transfer case. It is aluminum. I replaced it with another aluminum and it didnt last long, so next time I went with a after market steel one. So far it has worked fine. Hope yours is only a gasket but if it isnt, get you a steel one.

 

[kscheffler]

Hcannon: Where did you find the steel transfer case housing?

 

[HCannon]

kscheffler, The first time i replaced it my self. The second time I had Inland Truck Parts and Service put the steel one in. They charged me less for the steel housing than I payed for the aluminum one. I dont know where all that Inland has a shop. The one I used is in Lubbock, Tx. There no is 806 763 5329, they should be able to get or direct you where to get one if you are very far from Lubbock. Hope this helps.

 

[HHhuntitall]

Hmm, if it is just leaking between the case halves, just clean it up good and silicone it. I've fixed several like that, but with that low a miles, I'd be concerned with a crack. As far as a steel case, I'd bet they found a different t-case completely, such as a NP-205, which almost all had steel cases and were gear to gear instead of chain driven. I've abused many 205s and not broken but one, and that was when a driveshaft bottomed out and snapped the yoke off, which twisted out and broke the seal housing. I've used these guys several times, Transfer Case Express, Inc. · New, rebuilt transfer cases ( transfercase ). Lowest prices. In California, world-wide delivery, and they really know t-cases and trannies. They may be a little high, but for custom work, they are really sharp. If anyone can get a steel case for the 241, it'll be them. Also, look at the t-case you have, and if the tail housing is one piece from the rear seal up to the bolts that hold it to the case, it's a NP241DHD. If you have a two piece tail housing, you have a NP241DLD (light duty). Almost all the duallies will have the DHD (heavy duty), with the only exceptions I've seen being the '94-5 early trucks with autos.