i have a 98 d w/the 318 and the new process 242 transfer case when i put it in 4 i can't take it out with out driving around and make tight turns and then i sometimes hear a pop when it finally pops out.
i put on the lift at work with it in 4 and had some one jostle the front drive shaft with pry bar to pop it out
whats my major malfunction

 

the 242HD doesn't like to come out because the last sequence is the PT 4X4 position. This is a locking position like 4X4 Low. In 4X4 High there is a vicous coupler that allows movement beween the front and rear axle, however in PT there is NOT! It truely is a bad design as the PT should be next to 4X4 low and not the last in sequence back to 2wd.

What happens is as you come from 4 High (or low) it goes into this PT section. When it does there is movement to the front wheels that locks the front to the rear axles and for this to happen the front end gearing pushes forward and creates a bind on the T-case. You have to undo this bind to get it fully out of 4X4 PT.

To do this you can simply back up about 40 feet. Then turn fully to the right and back up about 8 feet, straighten again, the back up about 8 feet toe the left, then straighten. This in total I would back up about 100+ feet.

What you are doing in this sequence is making the front turn differently to the rear and un-locking this bind out of the transfer case.

In a different look, you could probably lift the front end up and switch the gearing back from 4X4 PT to 2WD and actually see the front end spin a little forward at least one gearing if that puts it in perspective.

The operators manual says nothing of this, but that's the way it is. Here is more info and you should read it all!

https://dodgeforum.com/forum/1st-gen...nv-242-hd.html
https://dodgeforum.com/forum/1st-gen...nv-242-hd.html
https://dodgeforum.com/forum/1st-gen...ow-hi-awd.html

 

yes i read those but i don't know sometimes it takes longer to pop it out of 4 and i will only try it on the grass so i don't bind the whole driveline up, and i don't know if it is shifting into the right position when i put it in the full time position the driveline still feels bind up

 

What exact positions do you have on that case?

2wd
4 PT
4 High
neutral
4 Low

 

2HI
4PT
4FT
N
4lLO

 

Yes, then you have the NV242HD Transfer Case. Never seen one on a 5.2L engine tho??????

Anyway, I used to shift on snow, dirt, and even mud; it still made no difference when going back to 2WD. The only way to correctly and fully get it out of 4X4 is the reversal technique. Then to ensure you are fully out make a very sharp turn on black top or concrete about 90 degrees and seed if you have front end hop. That would indicate whether you are still locked in, or fully locked out of 4X4.

 

thanks hydra i was just wondering i haven't used 4 for a while because i didn't want the transfer case or tran to blow up

i knew it was the 242 case because i saw the tag on it when i had it on the lift at work