First off let me say this, i didnt see this discussed anywhere else and i looked for a few days before posting now perhaps im blind and if this is the case im sorry,

i have a 1999 dodge durango SLT with the 5.2 and i have some transfer case issues, like the case its self is split and there is a hole roughly the size of a dime mabie a tad smaller, but needless to said there isnt a drop of oil in it and the wife has been driving it this way and didnt bother to inform me its making a "funny sound like a chain dragging" while i gather the chain is now prolly JUNK and rubbing the inside of the case i am on a very very very STRICT budget and i cannot afford to go and buy a new transfer case nor can i afford to let my truck sit while i am working it, (a day mabie two being the exception to that) i have been under it and i have figured out that it is the NP231D-HD and it has the 272:1 lo range ratio also it has Part time Full time 4 high and 4 lo and obviously neutral i have Two questions of the insane amount of wisdom on this forum, First can i be EXTREAMLY CHEAP right now and pull the transfer case apart and remove the chain and JB weld the hole back shut and fill it just to lube what is there (minus the chain, i want to leave it out because i cant afford one) and drive it this way for a few months untill i pick back up at work and can afford to replace it, or secondly my cosin has and has offered to me for free a NP 241 but it is out of a 95 chevy pickup is there anything i can do (im refering to swapping parts out of the 231 into the 241) to make it work in the durango i am aware of the obvious that if i put the 241 in i wont have PT and FT and all that good stuff i would just have 2h 4h and 4l i know that and its meaningless to me but will the rest work physical size bolt patterns will the input and output shafts interchange and will the stock durango drivesaft be too long/short? any advice would be great and if there are any members in southern michigan or northern indiana that have a 231d-hd they would part with at a resonable price i would be interested in that as well any help is GREATLY APPRECIATED and thank you all in advance

Below you will find the picture of the hole in the xfer case if i can figure out how to post it

 

I am gonna say that the 241 and 231 are not interchangeable that I have seen. From what your describing I am sorry to say a replacement is in order, and not to drive it if possible till you can fix it.
IF your strapped for cash, Id say your best bet is a junk yard. Just go around and find a D same year and transfer case and just pull it. I would say mabey $200 for the case plus two bottles of atf4 and your set. Just have to swap the newish one in of course. But be warned, if you do it this way you may or may not experiance problems...It will depend on the condition of the other transfer case.

 

if you had caught the hole before any significant damage was done iw ould say jb weld and fill it with fluid would work on a very temporary basis, however i think yours is too far gone for that, if you want to try it it definitely wont hurt it any more than driving it like you have been (ok your wife).

 

i figured as much but as i said i am on a very strict budget and cannot afford the extra 200-300 right now, i compared the 241 and mine tonight with my cosin and he seems to think he can make it work its just simply not going to be the same but i did find a 98 jeep grand cherokee tonight that i might possible be able to get the transfer case from for next to nothing and that jeep as well has Part time Full time 2 high neutral and 4 lo just like mine but it was sitting on the ground so im hopeful its a 231 thanks again for the advice and if there is any more advice to give please im all eyes... lol

 

chances are that the jeep has the same t-case in it if it has the same drive options

 

turns out the jeep had a 242j in it but im pretty sure if i change the input and output it will work it appears to be the same size and shape and all that good stuff does anyone have a link to a write for idiots from someone who has ever done such a thing?