Engine/Transmission (1998.5 - 2002) Transfer Case Snap Ring?

[EdK]

About a week ago I noticed a "gear" type noise... almost a rear end gear noise in my '99 2500, 5 speed with "HD" transfer case.

Well, then I noticed a "rubbing or grinding" sound when accelerating moderately. Closer observations showed the transfer case shift lever moving forward a couple inches just as the "grinding' starts!!! Placing the shifter in 4 wheel high stopped the problem, but it does it every time in 2 wheel high.



A local shop noted for building wild Cummins-Dodge pulling trucks seemed confident it is a snap ring that has come off or broken. Anyone experienced this problem... the shop guys made it sound like they have seen it a lot!!! Is it something I can get to, or should I surrender and let them fix it?



Ed K.

 

[Jeff Knight]

My 95 did it twice. The second time I needed to use my truck so I took the front driveshaft off and locked it in 4 hi until I could get it fixed. Putting it in 4wd hold the gears together and keeps them from grinding. Jeff

 

[kentdiesel]

There is a company that has a upgrade / fix for the snap ring. I t looks like you will only have to pull the rear housing off. I can not think of the website but I saved a shortcut to it on my computer at work. I will drop by the office tomorrow and send it to you. I had thought about doing this to my tranfer case and after I read your post I am definity going to.



Thanks,

Kent

 

[kentdiesel]

Here is the link to the snap ring upgrade.



www.drivetrain.com/gillies/Tcasesaver.html



If that does not do a search for gillies transfer case





hope this helps,

Kent

 

[Todd G]

I've replaced my snap-ring twice. They're easy to do. Here's how:



Remove 4 8mm bolts from the rear u-joint and pull driveshaft rearward out of transfer case. Make sure you mark the driveshaft and u-joint hanger so the go back together the same way.



Remove the 4 13mm bolts that hold the output shaft housing on the transfer case. You will find broken snap-ring here.



Replace ring with new one using good snap-ring pliers.



Seal housing and button back up.





It takes maybe an hour.

 

[EdK]

Snap Ring THANK YOU!

Thanks for the upgrade info!!! I'll order mine today. Just talked to the shop to see if they had the upgrade in stock... didn't know of it so I'll take a copy in. They said mine was a bearing failure this time, but the kit will be going on in a couple of weeks!!!!



Thanks again.



Ed K.

 

[Todd G]

I read on another site that you should replace the standard snap ring with one from a Borg Warner 1356 transfer case. Here's the link:



http://www.atra-gears.com/gears/sep01/taming.html

 

[EdK]

Two different style cases!

Todd,



The shop that replaced the bearing for me said there are TWO different style output shaft castings... one piece and two piece. I have a one piece, the kit you told me about will only work on the two piece. According to the shop, either can be found in many years.



By the way, the total job of removing the transfer case, replacing the bearing and repairing some "innerds" like detent balls and a broken spring, and reassembly ran $370.



Ed

 

[John]

Hey Kent...



the link you provided details the procedure for the NV241 (not the HD model). I'm just wondering if the snap-ring problem and associated fix applies to the HD version?



[and yes, I realize EdK has the HD version]



BTW, are you the "same" (NW BOMBer) Kent? If so, we miss ya!

 

[John]

Ed, the 2-piece transfer case tailshaft housing belongs to the NV241. The 1-piece tailshaft housing belongs to the NV241HD.



On another subject...



I've tried to locate a new replacement tailshaft bushing for my NV241HD. The dealer has informed me that the bushing is not sold separately. [hmmm... ] If I still want the bushing, fine...



I just have to pay my friendly Dodge dealer $280. and will receive the tailshaft casting and seal as a bonus.



But wait, there's more





(no, not really it just reminded me of those Ginsu knife TV commercials... )





Any ideas about procuring a tailshaft bushing for an NV241HD? (btw, this bushing resides just ahead of the output shaft seal)

 

[kentdiesel]

John,

I don't know if the snap ring upgrade applies to the "HD" transfer case. I'm not the NW bomber you mentioned. As for the bushing for the "HD" transfer case I would start calling transfer case rebuilders, maybe they would have a source for the bushing.

Thanks,

Kent (southeast)

 

[John]

kentdiesel, I found out at a NW BOMBer get together yesterday that you were in fact not the Kent I knew from our club. I was informed he moved to Tennessee, not North Carolina as your location states.



Thanks for the clarification though.



I've already started my search for the tailshaft bushing I need. However, anymore leads are surely welcome.

 

[EdK]

John,



The shop that correctly diagnosed my transfer case problem (OVER THE PHONE !) may be able to help with the bushing. They are equipped to do just about anything in their shop... as long as it's a Cummins and in a Dodge!!!



Their web site is: www.enterpriseengine.com or (740)246-6329



By the way... they pulled my transfer case, tore it down to see what other damage there might be, replaced a broken spring and a couple detent balls, and of course the rear output bearing that failed. Total out-the-door was $370 !!!



Ed

 

[John]

Thank you Ed...



I'll check into it.

 

[tgbol]

Does anyone know the size of the output shaft on the 241HD case? I think I need to do the snap ring repair on mine. I don't have the time to pull it apart to measure it before I order the parts. The Gilly's repair kit is only a shaft collar clamped on the output shaft to keep the bearing in place. Available at any bearing supply house.