I pulled apart a 1995 241DHD that I plan to put in my 96. I pulled it apart to make sure it's OK before I install it, since the one in the truck now pops out of 4wd-hi, and this case came out of a truck that the OD housing had been broken on.
I need to know what to look for as far as problems before I put in my 96.
I haven't found any rough feeling bearings or seen anything that looks like a problem with the shift forks. It appears the plastic/teflon pads are in place and nor overly worn, on the shift forks. I have not yet figure out how to get the bottom part of the gearing out, the part with the PTO gear on it. I have pulled out the chain and shafts the chain joins though. I can post pics if they would help.

Thanks,
Chris