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4wd System Refresh np241DHD rebuild.

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Well the time has come to tear into my NP241DHD,  I just bought an overhaul kit, ( seals and bearings only).  I will be dropping the transfer case at some point next week / weekend.  

 

Issues are I have a random grinding when I hit bumps, either in the CAD system or in the transfer case.  Pulling the stick back to 4x4 makes the noise go away, but I not longer have a working vacuum actuator either so I don't know if it CAD is to blame as I really doubt it is able to move the collar.  

 

I also have no ability to go into N or 4l in the transfer case.  It literally hits a wall trying to push from 2wd into N, so I am GUESSING that the shifter collar inside is FUBAR, but I won't know until I tear it apart.  

 

I am gonna go to the junkyard on friday and get a replacement CAD actuator and new vacuum lines as I can't even look at them without them busting / cracking.

 

Gonna take a bunch of pictures as I go.  

Also as a side note, I finally decided to figure out exactly what axle is under my truck.  It is a 610428-4  so a 3500 1994 front axle. nice to know rather than guessing.

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  • Me78569
    Me78569

    Big thanks to dynamic and his advice   The main shaft position is set by the rear main bearing in the transfer case.  

  • Me78569
    Me78569

    I honestly have no idea.     I do some cross checking on the parts.   Tyler and i should be a

  • Wild and Free
    Wild and Free

    A press is the best tool for changing the hanger bearing and Then spin balance it afterwards. Having worked at a shop with a driveline spin balancer it is amazing how little weight it takes to cause a

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  • Author

Yea,

 

I am hoping there is no carnage in the Transfer case, but I am really not going to be surprised if there is some pretty bad damage.

Typically grinding isn't good in anythings trans related.

Do you use 4wd pretty often?

  • Author

not really, I try to avoid it whenever I can, but it really puts a damper on the situation, when you need to use it but cant......

Yea I hear ya! Well hope its an easy fix, looking forward to seeing what you find.

HI guys, I had a similar problem with my np241 dhd. Maybe it's your struts and springs of the synchronizer.  Look in the dodge repair manual chapter 21-910 to 912. When I had drain the oil I had some pieces of metal...  it was the synchro springs,  I rebuid it but assamble the wrong way and when the truck it little bump makes a scrapping sound only in 2wd .   I had try in 4wd and nothing wrong.  So I disassambly the t-case and recheck the synchro. it was the cause. Make sure to assamble the struts and springs the correct way like in the manual!    

20 minutes ago, Mopar1973Man said:

If so... Then where is your write up on rebuilding transfer cases? 

Ugh... I've had it out and in pieces three times :doh: BUT if I can manage I'll be down in Springs with Nick :thumbup2: One of us should be able to snap some photos!

Have you ever pulled one apart Mike?

I don't know if any of the guts are the same as a 241dld but I have all of them from the a spare I got when the case halves cracked on my old 99'. Your welcome to them if they will work. My 2000 has the dhd so I'm definately looking forward to a write up :thumbup2:

  • Author

I honestly have no idea.  

 

I do some cross checking on the parts.

 

Tyler and i should be able to do a good writeup on this.

    • Like 2
    • Owner
    10 hours ago, TFaoro said:

    Have you ever pulled one apart Mike?

    No. Because I don't break things typically. Lets say I've removed transmissions and transfers cases typically for doing clutches.

    • Author

    Don't lie you break things, I saw the thread of your turbo trying to eat a clamp....

    • Like 1
    • Owner
    9 minutes ago, Me78569 said:

    Don't lie you break things, I saw the thread of your turbo trying to eat a clamp....

    LOL... Oh like I intentionally threw a hose clamp in the BHAF and put it back on... Right.... :rolleyes: 

    • Author

    like I intentionally kicked by 4wd selector to move it from N to 2wd when the wheels were all moving at different rates.... :shifty:

     

     

    oh no my shifty smile thing is gone....ahhhh:ahhh: fix it fix it fix it 

    Edited by Mopar1973Man

    • Author

    :shifty:

    whew it is back...

     

    I about went all jack sparrow on your and took over the ship. :shifty:

     

     

     

    ah much better

    • Author

    stupid computers making me feel stupid.

     

     

    so back to the truck, just ordered a replacement mopar center support bearing.  that should get rid of my highway vibration and also was likely the reason why the tailshaft of the transfercase was leaking slight.

    3 hours ago, Mopar1973Man said:

    No. Because I don't break things typically. Lets say I've removed transmissions and transfers cases typically for doing clutches.

    Never broken anything in the Tcase or trans on mine yet.... BUT when something doesn't work exactly how I want it to I'll tear it apart. Doesn't bother me a bit!

    1 hour ago, Me78569 said:

    so back to the truck, just ordered a replacement mopar center support bearing.  that should get rid of my highway vibration and also was likely the reason why the tailshaft of the transfercase was leaking slight.

    Might want to check the FSM and see if you need a bearing puller. I can't remember.

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