I will be disassembly my 241 DHD transfer case if my TC works out. Right now the transfer case clunks in both Hi and Lo. It seems as if the chain is skipping. I have inspected the CAD. It is in good condition.

Does anybody have and advice or tips/tricks to rebuild the transfer case? Is there any good resources on the net?

 

MY 97 manual cover the t case. If you are going to do a complete rebuild you will need to pull the case and do it on a bench. If you are only doing the chain then you can do it on the truck. You will need to pull the sprocket on the output shaft and then the chain can come right off. If I remember correctly there is a snap ring that holds the sprocket on the output shaft. There was a thread on this here about a month or so ago that listed a parts supplier on the web but I don't remember the name. I think a master kit was about $600 if my memory is right. I think the chain was about $150 or so.

 

 

I am going to pull the case. It is very hard to shift so I want it out of the truck to check that also.

 

im doing the same, except just replacing the seals, installing a t-case saver and putting a Goerend transmission in while im at it.

 

what's a t-case saver?

 

I think its only for the 241DLD. If I remember right it doesn't work or is not needed on the DHD. but its a bolt together collar that replaces a weak snap ring on the tailshaft

 

Could your clunk be the connecting collar between the transmission output shaft and the input shaft on the T Case?

 

n2moto - are you talking the large shift collar that works with the synchro?
I have the t-case apart right now and that collar shows signs of wear but nothing really significant.

 

Hey Bill,

Where did you find this picture? Is there a larger higher res image available? My T case needs a rebuild. I could use a service manual for a 241D but can't find one to save my life.

Cheers

Paul

 

Read the ghost print in the background.

 

Paul, two good ones to bookmark,
http://www.jameskowalski.com/Dodge/Parts/index.html

and here,

http://search.ebscohost.com/login.as...ile=autorefctr

Username; greatfalls
password; publiclibrary

Both sites require a bit of Adobe experence to reap the entire benefits, stick with it and you'll figure it out.