rwhite1

Last night my transfer case started making sounds (growling and popping). TCase handle was vibrating a little - moved the handle forward and noise stopped. Finished driving home.

Problem: Now the transfer case shift handle is in what should be the neutral position but is in 2Hi. Where 4Lo should be is Neutral. I am locked out of and can not move the Tcase shift handle to where 2hi or 4hi should be.

What could have possibly happened and is this something that I could take on myself (mechanically inclined but have never been inside a tcase)?

Tcase is a 241 DHD.

Thanks.

rebal

its not by chance coming off the trans?

gorms

I'm not sure if this applies to the 241hd, but on my old 231 (very similar case) there is a snap ring on the output shaft against the outboard bearing (behind the tail housing) that is prone to popping off, especially if it ever gets re-used during a disassembly. It worked its way off on that truck and the shift handle was in a similar place to what your saying to stay in 2wd, couldn't shift into any 4wd, and there was grinding on accel/deceleration.

Also could be worn out pads on the shift fork, and although I doubt the linkage could have shifted that much just while running it's worth looking at the rod that connects the shift handle to the lever on the t-case.

SIXSLUG

Time for an all over inspection, start on the outside and work your way in.

T-cases aren't hard to work on, just find a good manual for it, its in the Dodge FSM, and start digging if the outside looks good.

Fluid level is important, have you checked it lately?

dukektm

Same issue here. Handel is where n should be but it is in 2hi, pops into 4hi under acceleration which would be where 4low should be. No grinding noises but it feels like the hubs are engaged full time. Ideas?

rwhite1

Not sure - I pulled mine last night and took the tcase to the mechanic this morning. I'll post what I find out.

rwhite1

Watched it get taken apart. Input bearings in the back are shot. Somehow must have gotten starved for oil and they were the first to go. Chalk it up to an inexpensive (considering what could have happened) lesson - always check transfer case fluid.

SIXSLUG

Many of our trucks drip fluid at the rear driveshaft seal.

I had to replace mine twice before it quit dripping, but I still have the sling stain on the frame and underbody, so I know it still weeps once in a while....