x2 Its not hard to tear these apart.

I would say that your input shaft and the sliding shaft that locks it into 4hi is probably bad. The pads being worn can cause the shaft to not engage the splines fully and they can partially shear which will also cause it to jump out of gear. I know cause that happened to me beginning of the year. Mine jumped out of gear so hard it broke the collar and trashed the fork.

You might be better off finding another transfer case. or swapping in a 271.

 

So, this could be a fairly easy task, or it could be a major rebuild? What is the 271? Is it a heavier case? What did they come stock in? I might be better off taking it to somebody.

 

271s came in the 03 and newer Dodges. It was also used in late model Fords. It is a bigger heavier transmission that will require some driveshaft work and a bit of clearancing on the frame rail. I have a thread about it on here somewhere that has a few pictures. It's not that hard if you are fairly mechanical inclined.

Or else you could just find a another 241(which is what you have). The problem you might have is how many parts are junked. On mine the cost of the parts would have exceeded the cost of a rebuilt one. So thats why I swapped in the 271.

If its cheaper to rebuild yours than I would say do that. The strength of the 271 really isn't needed unless your doing some high horsepower stuff. I see 241 in the classifieds for 400-500. The cost of my 271 swap ended up being about 1k or so with the driveshaft work.

 

I made over 800 on my factory 241, but it was probably on it's last legs!

 

The shop I will probably use wants 250 plus parts. A master rebuild kit is around 500, I believe.

 

I have a transfer case saver ordered from quad4x4, and as soon as I can save a few more pennies I am gonna pull it and have it rebuilt. Anything I should have them do, or certain parts I should go ahead and get?

 

I pulled and disassembled the case last night. The pads on the mode fork were worn, and one was cracked, the sliding clutch and stop ring have some damage from the gear grinding under load, the input shaft bearing came out in pieces. The cage that holds the ball bearings is GONE! Well, not gone, but attached to the magnet in the form of a furry metal mess. Nothing else seemed damaged, but I am going to replace the thrust washers in the planetary just in case. The other bearings look good. All you need to disassemble this case is a set of sockets and a good pair of snap ring pliers. It just comes right apart.

 

All right. Everything has been re assembled and running for a while. No problems, and it shifts in and out of gear better than it ever has before.

 

sweet. Congrats

 

when the t case is on its way out , does it pop and clunk when under pressure ? mine does it in 4lo and 4hi . i think thats whats going on with mine .