i just got a case for mine and i got it from TCE
http://www.transfercases.com/

mine was only 550.00 (i think they had/have a little special)
it was also not worth returning the core. its only 100.00 IIRC.

 

My problem right now is that some ******* cracked the rear tail shaft on my t case and tried to JB Weld it back together. Not only that, but they took the tag with the gear ratio on it as well... Does anyone know the gear ratio fora 1996 5 speed V6 tranfer case? It was made in March of 06. If you could help me, I would be greatly thankful. I cant even get parts for this thing until I have that gear ratio #.

 

OK .. job is done .. It was not easy, but it was worth it.
Getting the case in and out is not easy. I made some modifications to the tortion box crossmember to make it go easier in the future.
The new chain does not slip and does not slap the case anymore.
I have some pics of the internals of the transfer case. I forgot my camera today, so I don't have any pics of the install or my mods to the crossmember. I will post some pics of my corssmember in the future.

Alright some pics.

First oneis the old chain vs the new.. It was about 1/4" longer. Does not take much slack to cause some problems.

http://i17.photobucket.com/albums/b7...g?t=1167537817

http://i17.photobucket.com/albums/b7.../camera273.jpg

http://i17.photobucket.com/albums/b7.../camera276.jpg

http://i17.photobucket.com/albums/b7.../camera275.jpg

http://i17.photobucket.com/albums/b7.../camera274.jpg

http://i17.photobucket.com/albums/b7.../camera272.jpg



The rest of the pics just show the guts of the case.

 

How much could you move the chain while it was still on the sprockets? Mine moved about a quarter of an inch at least. My interior case looks identical to what you posted, except for the fragged tail shaft. From the looks of you pics, my chain is definately the problem. The gears on the shaft are pretty clean and there are no pieces of metal floating around so I think that it will be fine. Nice ballisong BTW and where did you find your chain for 70 bucks? I have been everywhere and have found nothing under 96.

 

The oldchain was pretty loose on the gears, it moved at least 1/4". I think the inside of the chain was worn along with the stretch. The new chain fit tighter on the gears.

I got my chain from a local shop called Valley Gear. They have a huge stock of parts.
If you want me to get you a chain let me know. I think it ended up being almost $80 after tax. So, after shipping you will be near $90. But, I can guarantee it will be the right part.

 

Thanks CADster, I had ordered one this morning for about 685 plus core and mail chages. Was able to get it from the same place as you for 595 ( Sale is over!) plus core and mail charge. mechanic said my bearings were bad and so was the chain. They found some shavings in the fluid so I think it was best to let her go. This new one is a rebuild w/a year warranty. Hopefully it'll restore my faith in my Dakota. I'm also looking at putting in a new exhaust and Cat converter, they're worn as well. I'm looking at Flowmaster 40 or Dynomax anyone out there got experience w/either?

 

since you have the 3.9 I would go with the flowmaser 40.

 

now a question about the cat converter. shops have quoted me 300 to replace it, but looking online it'll run me about 125, is it really 175 in labor??? I'm thinking I should just buy it and have it put in by the shop

 

Do not pay that for a cat converter. There is very little work to be done for that install, are you sure that there is not some other work being done? I would not pay a penny over two hundred installed, that is a very fair price. Any more, and you had better be getting exhaust pipes too.

 

I got a magnaflow highflow cat for my 99 and it was only like $75.

I would buy one and take it to same guy that does it on the side or has his own buisness. the bigger shops try to rip people off.