2nd Gen Non-Engine/Transmission Transfer Case

[Todd G]

I have been having a problem with my 241LD transfer case for some time. It makes a sound like it is going in and out of 4wd violently. I have taken the case apart several times and each time one of the synchro struts and the synchro spring towards the front of the truck is in the bottom of the case on the magnet. I can't figure out why this is happening. Everything inside the case looks to be in good shape and the shift lever is easy to move. I have followed the service manual to the letter each time. I have had output snap ring failures in the past and wonder if this started the problem.



Any ideas?

 

[csutton7]

I was told that the factory snap rings are pcs of ***t-along with some other parts(don't remember the others)--did you replace them in kind???? If so look to get some upgraded ones--- www.transfercaseexpress.com --call them -they are good----chris

 

[Extreme1]

If the synchro spring doesn't have enough preload, it won't stay in place. I noticed mine seemed weak so I bent them open to apply more preload. They've worked fine since. That was 4 years and many miles ago.

 

[Todd G]

I bent mine out the last time it was apart and it still makes the noise.



Chris: I did call the shop you mentioned and they suggested it might be a motor mount I checked and the motor is rock-solid under torque. They also only sell complete cases, not parts.



I guess I'll have to call around to a few more places.

 

[csutton7]

Todd--dang I thought they sold parts--when I bought my 241 HD there(Oakland) I'm almost sure he told me they did(2yrs ago)--maybe I misunderstood--sorry--chris