I'm afraid my transfer case is gone, but wanted to run through what I've checked and see if I'm missing anything.

1994 Dodge Cummins 3500 4x4 120k miles, manual trans.

1. Front drive line wont spin by hand with 4x4 engaged, in gear, engine off.
2. Removed the CAD and moved the 4x4 lever in and out. Confirmed the fork is moving back and forth. Feels tight (cant push the vacuum back by hand.)
3. Jacked up both front wheels. They spin independently with 4x4 off, and opposite when engaged.
4. I pushed the collar over the central axel and put the CAD back on, 4x4 engaged. Tried to climb a small hill and got no front wheel spin. had the floor mat out at the time and could see the front axel spinning though...

I'm afraid its the transfer case, which would be beyond my skill (and tool) level to fix. Is there anything else it could be? I browse this site quite a bit and love it. Thanks for any help on this....me not being a regular and all....

 

Yep, your transfer-case seems to me that its shot, or somethings not engaging like it should. You should ask MonteC for some advise.

Here are my things you should try and check:
The transmission/transfer-case fluid
Try driving with the transfer-case in N then come to a stop, then put it in 4-L, then take it into 4-H after making another complete stop.
Flush all the fluids in your transfer-case and change the filter in it.
Check if your trans-pump is working.

After you do this, and still no 4x4 come back, and I will give you some other solutions you can try.

 

Does the light in the dash come on when you engage 4x4?

It sounds like everything is doing what it should..... What can you see thru your floorboards? Does the front driveshaft turn while you are out wheelin'?

 

FarmBoy,

Thanks for the tips, I'm gonna work on your ideas tonight.

For Heyyou, what I should have said is, i took all the interior floor liner out for cleaning and having the seat re-upholstered so I'm just looking through the shift column grommet hole. The front drive line is spinning while the back wheels are spinning out (loss of traction) on the hill. I get no help from the front wheels, they wont engage.

It's not easy looking through that hole, spinning out on a hill and sitting on a 5 gallon bucket!

 

an easier, better, and safer way to debug things is to put it up on 4 jack stands and have a driver crank it up and run it.

at first glance, it appears that your front axle is locking up properly, but with the truck under power from the rear, its impossible to tell whether the rotation of the front drive shaft is coming from the t-case, or just freewheeling because the front axle is locked and spinning.

put it up on stands and run it. if the front drive shaft is spinning, then t-case is ok.

 

Did your dash indicator come on for the four wheel drive?

The four jackstands idea will work great.

 

Hey no prob, just trying to help all the great friends that drive the long lasting 2nd Gen Rams.

 

The 4x4 light is coming on when it should. The wife is picking up jack stands on the way home from work, good idea. I hate to admit it, but I was unaware the TC had a filter...is that behind the plate on the right (passenger side)?

 

there is a plate with i think 5 bolts? but make sure your trans fluid is warm. its just like changing your oil on your motor just a bit harder. be sure u have all the new fluid, filter, other parts you may need. And oh yeah tell your wife when she picks up those stands make sure there rated over 3+ tons. I don't wanna hear about your death on the news if the truck were to fall off the stands. Just giving a tid bit of advise. Good luck.

 

sorry, no filter on t-case that i know of. just a drain and fill plug. 10mm hex.

regarding changing t-case fluid - while this is good maintenance, its NOT going to solve your immediate problem. the t-case is much like a manual transmission - its all gears and chain, and unlike an automatic transmission - its not a hydraulic device. the oil inside it is just for lube and cooling purposes. so don't waste your time changing it right now.