okay guys, i need help. 4wd has been out on my 94 ram1500 nv3500, 318, np231. i went througt the whole CAD and it is working tip top now (4wd light stays on). however i am still not getting any power to the wheels. WHen i am in 4wd there is an awful rattling noise coming from the system, almost like a very loose chain hitting the casing on the t-case, but i am not sure if that is it or not. in 4wd, the driveshaft cannot be spun by hand so the t-case is locking in, so even with a loose chain i would expect it to send power? Also, in 4wd going around a tight corner, the front axle does not hop as it used to when the 4wd was looking. Am i looking at a blown diff or broken axle shaft instead? Has anybody else delt with this. I guess i just want to know if i need to replace the t-case, axle, or both.

Thanks alot!

 

can you put it up on 4 jack stands and run it. check front drive shaft. if spinning - then the t-case is working. if not spinning - then the t-case is broken. possibly a busted chain, or gear, or who know's what.

the vacuum operation of the cad comes from the flipping of the vac switch in the t-case. so it takes a lot of successful motions to spin the driveshaft and lock up the cad.

no personal experience, but very good pricing.
http://www.transfercases.com/

for repairs, the chain is replaceable for about $100

 

Thanks! i really think i need to either replace the t-case or the axle, i just don't know which one. i would really rather not replace one to find out it was the other, lol

 

to prove its the t-case, remove front drive shaft and operate t-case.

 

is a transfer case rebuild or chain replacement something a mechanically inclined home tinkerer could tackle?

 

yes. there's some how-to scattered around this and other forums.
for removal and replacement, other than being heavy, its just a few bolts.
i've got no personal experience on the insides of it, but it seems doable.

http://4x4trailhunters.com/tech/read/20



edit - oh i almost forgot. a very common problem with these t-cases that causes a grinding noise is a broken snap ring at the rear output shaft. this can be checked/fixed by removing the tail housing only, while t-case is still in the truck. i think its part number 31 in the exploded diagram.

 

thanks! very helpfull

 

Thanks for that info Dhvaughan.....Thats something ill keep in the back of my mind.

 

okay, i found the problem! the two half shafts at the CAD are misaligned, not allowing the collar to link them. The shafts are almost floppy here. is there shims or an alignment pin missing/broken. Now i have the problem and need a solution