Engine/Transmission (1998.5 - 2002) Vibration

[SAndreasen]

So I've got a bad vibration on my ex cab 98 it has a one piece driveline well the vibration got so bad it broke the front u joint on the rear drive this came apart so bad it broke the adapter housing on the transmission to transfer case . When I bought this truck the guy said it had a bad vibration before the shift tower bolts fell out and he towed it home I replaced the bolts still a vibration so I pulled the transmission and found one tooth gone on the transmission input shaft I replaced the input shaft new bearings new seal . Well shortly after I did this the fifth gear broke on my other 98 so I took a chance and put the transmission with the broken tooth now replaced input shaft in this 98 no vibration what so ever . So I'm thinking it's got to be the transfer case I put new gears on the transmission with the broken fifth gears put that transmission back in the ex cab bad vibration and then broke adapter . How much slop is the chain allowed to have in the transfer case np 241 dld ? What other things should I check in the transfer case bearings seem fine but there is a lot of slop in the chain not so much that it's rubbed on the case though . I also ran the truck through the gears with the rear driveshaft out and the vibration was really bad took the transfer off which wasn't hard took front driveshaft off and slid off didn't even have to undo any bolts . The vibration was gone. Any ideas ?
Thanks Shaun

 

[SAndreasen]

So I had a 2wd extension housing and I bolted in place of the broken 4wd housing filed trany full of oil and ran I through the gears again and the vibration was gone now so its Gota be the transfer case.

 

[SAndreasen]

pic of 2wd extension housing

 

[Sticks]

There should be a chain tensioner in that transfer case. IIRC just a plastic shoe on a spring much like some timing belt/chain setups.

 

[SAndreasen]

Thanks I'll go look and see I never saw one when i took it apart I'm going to get a different case anyway this one has been broke and welded twice. The chain has almost 2 inches of slop in it but that was really the only thing I could find when I got the truck the bolts at the rear of the extension housing were all loose barely holding on and I think maybe something got out of line and is causing the vibration.

 

[CM_Guest]

If I'm not mistaken there is a "heavy-duty" NV271 transfer case available that might be worth looking for if you're going to replace your existing one. May as well upgrade at the same time if possible and affordable.

 

[SAndreasen]

I've seen those cases around I would like to get one of I can

 

[SAndreasen]

I found two used transfer cases but they are not 241 dld they 241c swapped the planaterys around form the case I had and now its ready to go in and see what happens

 

[SAndreasen]

Got everything back together and I've ran it about 1500 miles and no vibration or anything there are some differences between a 241 and 241c the input shaft has to changed and the bolt pattern is different on the front of the case to transmission adapter housing pretty simple to swap a few parts around to make the 241 work you won't have a vacuum switch for front axle engagement but that was fine with me since my vacuum system isnt working anyway . So all in all got the quad cab 24 valve I traded for with bad transmission and bad transfer case up and running for under 200 bucks cash some scrounged junk yard parts a little time in the garage