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Old 11-07-2010, 12:45 PM   #1 (permalink)
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transfer case rebuild

i have a 1998.5 dodge 2500 slt extended cab 4x4 24 valve with a 241 t case. it is not the hd case. im going to rebuild my case next weekend. i have a kit on its way from monster transmission and performance. im rebuilding it cause i have a bearing out and there's not point in tearing the case apart and just replacing one bearing. but i need help. i've never been into a t case before. any tips would be helpful and if any one knows of a web site or something that shows how to rebuild one that would be great. thanks a lot guys!!!!!!!!
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Old 11-07-2010, 07:12 PM   #2 (permalink)
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TC's are quite easy to rebuild. Just keep track of needle bearings if equiped and location of snap rings. Pay attention to oil pickup tube and not damage. Piece of cake. Take pictures if necessay for us with short memory.
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Old 11-07-2010, 07:59 PM   #3 (permalink)
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i was planning on taking many pictures. thanks for the help. is there any specs that i need to know about when going back together?
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Old 11-15-2010, 01:22 AM   #4 (permalink)
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Just subscribing... my tcase is majorly Fd up but dont have much money right now to buy one and dont know how to rebuild one. Mine slams into neutral if i hit the gas hard when in reverse, makes cracking/grinding noise when accelerating from a hard stop (if i let off the gas, move tcase shifter from 2wd to 4wd then back to 2wd it kind of "resets" it and the crackin noise goes away and i can continue to apply a load) also locks itself into 4wd when in 2wd and make a very sharp turn
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Old 11-15-2010, 08:23 PM   #5 (permalink)
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Originally Posted by 02-24v View Post
Just subscribing... my tcase is majorly Fd up but dont have much money right now to buy one and dont know how to rebuild one. Mine slams into neutral if i hit the gas hard when in reverse, makes cracking/grinding noise when accelerating from a hard stop (if i let off the gas, move tcase shifter from 2wd to 4wd then back to 2wd it kind of "resets" it and the crackin noise goes away and i can continue to apply a load) also locks itself into 4wd when in 2wd and make a very sharp turn
sounds like your shift collar is shot and probably your gears to but you might be so lucky to have the shifter out of adjustment
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Old 11-15-2010, 08:24 PM   #6 (permalink)
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a good site to find almost anything is ALLDATA Online - Automotive Diagnostic & Repair Information
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Old 11-15-2010, 11:24 PM   #7 (permalink)
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thanks man. Sounds like itd be worth it to rebuild? no cracks in the case, checked for that..
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Old 12-29-2010, 08:31 PM   #8 (permalink)
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ive replace the shift forks and pads and synchro struts and ring in mine 3 times. i guess i wasnt doing something right. so i just dropped it off at a local transmission shop to rebuild it. turns out my chain is stretched then i had bad bearings and gears. also the spindle that the chain sits on is eaten up. theyre charging me 1600 to fully rebuilt it with all new parts and updated snap rings. i coulda just bought a new one for that price, but the good part is that theyre giving me a 5 year unlimited mile warranty on it.
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Old 12-30-2010, 01:56 PM   #9 (permalink)
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Just subscribing... my tcase is majorly Fd up but dont have much money right now to buy one and dont know how to rebuild one. Mine slams into neutral if i hit the gas hard when in reverse, makes cracking/grinding noise when accelerating from a hard stop (if i let off the gas, move tcase shifter from 2wd to 4wd then back to 2wd it kind of "resets" it and the crackin noise goes away and i can continue to apply a load) also locks itself into 4wd when in 2wd and make a very sharp turn
Could very well be your shift collar, but you could have also thrown your synchos off of the hub (as they are held on by two small snaps) and eaten through your stop ring. Try adjusting your linkage to see if that makes a difference, set up more toward the neutral side of 2wd than the 4wd side. You can also reverse the coupling on the CAD to lock the front axle and see if that makes a difference. Just got done rebuilding mine, same noise and problems from mine, I tossed my rear main output bearing which wrecked havoc on the syncho assembly, planentaries, and all my bearings. Try transpart warehouse out of vegas for parts, they strip down old tcase and sell the usable parts.
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Old 12-30-2010, 10:53 PM   #10 (permalink)
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Hope this helps: NP 241DHD Info
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