241 DLD problem
 

I am having a problem with my transfer case, I pulled it out, tore it apart and nothing looked out of the ordinary , so I put it back in my truck and its still doing the same thing it was, it is actng like it is in neutral but it makes a loud grinding noise but only when the truck is in gear, just idling in neutral it doesnt make any noise at all , any ideas?

umm...are you sure its the t-case?

Im pretty sure, the transmission doesnt make that noise if i start my truck and shift it with the t case out

is it possible the 4wd actuator on the front axle is bad causing the splines to be partially engaged?

check your pinioun gear and bearings my 95 did same thing once when the bearing went out it chewed up my shim plate and pinoun gears to

i'm with blue thats what i was thinking also was the rearend

It does it with the driveline out , both front and back, it only makes the sound when the t case is in the truck, when i shift it without the t case in it shifts normal and no noise

When your rear drive line is out, check to see if the output shaft on the tcase has forward and backward movement. A common case with the 241 is there is a snap ring in the tail housing that keeps the shaft in place, sometime that snap ring will break causing the shaft to move back and forth. Thus moving all the gears attached to it, commonly moving the synchronizer gear sleeve on the 4wheel drive gear causing wear, so if that is the case, check to see how worn that sleeve is.

I pulled the tail housing off and there are 3 snap rings, one against the bearing in the tail housing, and 2 on the speedo gear, is there another one im not seeing?

Seems to be all there. The one against the bearing is what keeps the shaft in place, did you try moving the shaft to see if there is any play? If it is the tcase causing the noise, it might be something further inside, the tcase is pretty easy to take down and put back together if you wanted to try that.

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I have everything torn down to the second shift fork (the smaller one) and so far I cant see anything worn or tore up, How do I know if the collar is bad? it looks like its in good shape

did you pull the input appart? check the thrust plate and snap ring, if there bent or broken it will cause the noise your talking about.

No but I will do that tomorrow night after work and I will let you guys know what I find, how much do they cost to replace do you know?

depends on what is broke ... I'm thinking its either that snap ring or the thrust washer both are pretty cheep

Thank you sir! I know I was going to tear it apart the otherday but havent had time, i will do it right now

Turned out the range fork had the plastic clips worn off it and the shift selector( that gear thing thats in the range fork) wore a 1/8th inch groove in the fork, some how the gear thing got in front of the fork instead of being in the groove and the back side of the gear wore the fork down, I hope this fixes my problem

Ah thats the synchronizer sleeve, what I thought was the problem, but not the way I though. :tu: Glad you found it though! hopefully your rig will be up and running in no time now!

I appreciate all your guys help, I really do! I ordered a new fork today and should be here saturday, Im gonna be happy to have it back, I have missed it lol

Were did you get the parts? I need a rebuilf, I have a slamming noise,when goin to reverse I hear in the case and the fork is worn the same way and not goin in 4wheel till I move the plate to engage the chain with my hand.

I got it all through U joints unlimited here in albuquerque,nm