Last week I found that I have cracked my case on my '95 Ram. I found another but the input shaft to the tranny is shorter then the original. The manufactured date on the original is '94, the replacement is '96. Both are 231d cases.

The questions are:
Why is the inputs a different length? trannys appear to be identical.
Can I swap the shafts from the transfercases?
Will a T-case from a V10 swap to my stock tranny?

Here are a couple pics of what I'm dealing with. the replacement are the dirtier/rusted parts.

 

This site will help. http://www.drivetrain.com/parts_cata...ge.html#Dakota

 

I ran into the same problem a few months ago. It is possible to switch the shafts but it will require a complete disassemble of the transfer case, and the only special tool you will need are a good set of snap ring pliers (you will break cheap ones). I personally would recommend switching the shaft and planetary gears as a set, because of tolerance issues that can occur.

The differences between the two is that 94 and 95 use 46rh transmission (hydraulic shift transmission) and 96-01 use 46re (electronic shift transmission) The "rh" uses longer shaft on the tcase, while the "re" uses the short shaft. the longer shaft of the "rh" will not bolt behind a "re" trans, because the tcase will bottom out before the flanges are flush.
i don't know if a v10 tcase will work behind a stock v8 trans

 

I appreciate the info. I figured I would have to dissassemble after seeing an exploded view. I went to the drivetrain site listed above and it looks like the V10 t-case will have a different spline count.

I use this truck for offroad use. Are you familiar of any way to double the t-case?

 

try http://car-part.com and find a t-case from a 94-95, tha would be your best bet IMO

 

why u have it apart id install to t-case saver. replaces the snap ring on the output shaft. if that one snap ring fails its good bye t-case

http://www.quad4x4.com/Dodge%20Trans...se%20Parts.htm

 

Is there any specs and tolerances I should know about?

 

Any other input?

 

Swap input shafts, it's not difficult. A set of snap ring pliers, a tube of Ultra Black RTV, and new seals is all you really need.

The only problem here is New Process changed the gear pitch on the input shaft assembly midway through '94. If the original has a post 94.5 manufacture date, it has the new style gear cut. Pre 94.5 it has the old style gear cut.

Now, even if your case is pre 94.5 you're still in luck. If you didn't crack the front half of the original case, you can use it instead of the '96 front half.

Here's my write up on swapping to a 231 or 242 in a Grand Cherokee, the tear down will be very similar. My way involves removing ONE snap ring to remove the input shaft. Most others have you disassemble from the rear of the case.

http://www.jeepforum.com/forum/f13/n...pdated-685644/

 

Thanks for the info. Onr thing, the front if my case is cracked. Will the '96 work OK?