Won't shift to 4wd

[Scott91370]

Stopped at the tranny shop today.  T-case rebuild runs from $450-$750 depending on what parts are broken.  I need to find out where to buy these parts and I think I can build it myself.  The exploded view doesn't look to bad.  Anybody here ever rebuild one?

[Motorbrreath]

i can send you the step by step. its not that bad at all.

as for parts, make sure they are mopar parts!

[Cumminalong]

as for parts, make sure they are mopar parts!

Why do that?.....getting the parts through Mopar will double the cost.

The t-case isn't a Dodge part, it's a New Venture.

You can find the rebuild kits on those a LOT cheaper.

If it's not under warranty, you'd be nuts to pay dealer cost on those parts.

Now, if it was a Dodge specific part, yeah get the Mopar part. But, like the engine parts on the Cummins, you'd be getting it through 3rd and 4th party and paying the mark up.

[Motorbrreath]

as for parts, make sure they are mopar parts!

Why do that?.....getting the parts through Mopar will double the cost.

The t-case isn't a Dodge part, it's a New Venture.

You can find the rebuild kits on those a LOT cheaper.

If it's not under warranty, you'd be nuts to pay dealer cost on those parts.

Now, if it was a Dodge specific part, yeah get the Mopar part. But, like the engine parts on the Cummins, you'd be getting it through 3rd and 4th party and paying the mark up.

your right Rich, i guess i shoulda been clearer. what i ment was dont run aftermarket cheapy parts in it

[Cumminalong]

your right Rich, i guess i shoulda been clearer. what i ment was dont run aftermarket cheapy parts in it

Choke yerself!

[Scott91370]

Those step by step instructins would be great: shcermak at yahoo dot com

Are there any names of brands I should stay away from?  Any what names would have better quality?

Thanks guys...

Edited to keep the email from getting hammered...

[Motorbrreath]

your right Rich, i guess i shoulda been clearer. what i ment was dont run aftermarket cheapy parts in it

Choke yerself!

*leans forward*

[Scott91370]

This listing is for a 241 DHD transfer case . This case is from a wrecked 99 ram 2500,That was rebuilt less than a year ago. If your transfer case has an assembly number  5210-5028 This is the exact one.  Fits: 1998-2002 Dodge Ram 2500 Truck 23 Spline front input, 31 spline slip rear,  Without speedo hole, synchronized, w/PTO, automatic transmission.

Found this one for sale.  Sitting at $250 right now.  Is there anynody in the area of Jamesville, New York?  seller doesn't want to ship and I'm in Texas. 

Guess I need to pull my case today and count some splines.  Only thing I didn't like is the guy sprayed primer on it (the whole thing, including the tags).  Another reason for me to get a complete one is that a while back one of the studs snapped off on my case and when I tried to remove the broken part my ez-out snapped in the hole I drilled.

[Scott91370]

Anybody know the difference between the Range Fork and the Mode Fork? I did some searching but some people call 2wd-4wd range and some call it mode and some call 4h-4l range and mode.

[Scott91370]

Case out.  Haven't opened it yet but looking into the holes where the output shaft from the tranny goes there is some pretty good size pieces of metal (1/16" long x 1/32" x 1/32").

I thought soembody posted they had a step by step on rebuild, is this the one you have from the manual?

DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in case.

EXTENSION HOUSING
(1) Remove extension housing snap-ring access cover.
(2) Remove bolts holding extension housing to rear case half.
(3) Tap extension housing with plastic or rawhide hammer to loosen sealant.
(4) Disengage extension housing snap-ring from rear output shaft bearing.
(5) Separate extension housing from transfer case.

COMPANION FLANGE AND SHIFT LEVER
(1) Shift transfer case into NEUTRAL.
(2) Remove companion flange nut (Fig. 3). Discard nut after removal. It is not reusable.
(3) Remove companion flange from front output shaft. Use a suitable puller if flange can not be removed by hand.
(4) Remove companion flange rubber seal from front output shaft (Fig. 4).

FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove output bearing retaining ring with heavy duty snap-ring pliers.
(2) Remove output shaft bearing.
(3) Note position of bolts that attach rear case to front case (Fig. 6). Some bolts/studs at ends of case require flat washers. Mark position of these bolts with paint or scriber.
(4) Remove rear case-to-front case bolts.
(5) Loosen rear case with pry tool to break sealer bead. Insert tool in slot at each end of case (Fig. 7).
(6) Unseat rear case from alignment dowels (Fig.8 ).
(7) Remove rear case and oil pump assembly from front case.
(8 ) Remove shift rail cup and spring (Fig. 9).
(9) Remove front sprocket retaining ring (Fig. 10). Pull mainshaft, front sprocket, and chain outward about 25.4 mm (1-inch) simultaneously (Fig. 11).
(11) Remove chain from mainshaft drive sprocket and remove front sprocket and chain as an assembly.

I'll stop here since it's quite long... I'll try and get some pics after I get a work table set up.

[Scott91370]

Finally got it all apart and it is the smaller of the forks: the range fork.  The pads have melted away and a groove has formed in the fork itself.  Also one of the retaining rings came off (which I am sure is what cased the rest of the problems) and needs to be replaced. There was no metal in the case (normal very fine stuff on the magnet) and all the gears look like they are brand new.

 Now to find the parts. Here is what I am going to buy (something like this):
1) Gasket/o-ring set: http://cgi.ebay.com/ebaymotors/NP241-Transfer-Case-Gasket-and-Seal-Kit-_W0QQcmdZViewItemQQhashZitem230a008d63QQitemZ150491663715QQptZMotorsQ5fCarQ5fTruckQ5fPartsQ5fAccessories

2) Range fork: not even sure where, thoughts?

3) Retaining Clip: not even sure where, thoughts?

I'll get some pics of the bad fork and parts.

[Buford445]

I'm on my phone so I didn't go to the link, but go to Request a Quote from Dave ( Parts/Service ) he should be able to help you

[Scott91370]

Pics:
Retaining Clip for Range Fork.  Hard to see because it's a phone pic, but the clip itself has a bevel to it.


Range Fork #1... Melted Pads.


Range Fork #2... No pads, but some good grooving going on!

[Scott91370]

In doing some research, I found a fork pad kit.  Of course the idea of $10 vs. $80 to fix it is great, but what do you guys think of the wearon the fork.  Is it going to be too much? (I'm leaning towards yes just for peace of mind.

[Scott91370]

I'm on my phone so I didn't go to the link, but go to Request a Quote from Dave ( Parts/Service ) he should be able to help you

Good thinkin!