The transfer case is a NP-231D 2.72. All was fine until a couple weeks ago, it started making a sound like a bearing was going out but if I speed up it would go away, then there started to be a clunking sound that would make the truck shake a little bit, but it was only if I was excelerating at a normal pace, if I excelerated really slow no clucking. I have pulled the case off and have taken it apart and found that there are aluminum shaving in the case, after take it further apart I found that the range fork has a grove from the 4 wheel drive gear in it. What would cause this?

 

do you have a broken snap ring on the output shaft or elsewhere ?

 

I found one in the extention housing, not sure where it goes though. It seems as though all of the bearings are tight. I attached three pics, the range fork, the drive gear and the selector.

 

Here is the Selector pic. its when the Transfer case is in 4H is when the fork is grinding against the drive gear.
http://file.goodnetworking.us/selector1.jpg

 

Does anyone have a good breakdown image of the NP-231D case so that I can compare parts?

 

hard, unclean shifts between 2H to 4H and 4L are normal causes of damaged forks...a damaged range fork can easily cause damage to the gears...the aluminum shavings are most likely from the "grinding" between the 4H gear and the range fork..other than what you have already done, I would also check the u-joints on both ends of the front and rear driveshaft...wobbling driveshafts caused by worn out u-joints can potentially damage the transfer case internals

 

Here is where the Transfer Case Saver goes. http://www.drivetrain.com/parts_cata...ase_saver.html

 

I found the problem, the snap ring that I found in the extention housing, like dhvaughan said to look for, is what holds the main shaft in place from sliding to far to the front of the case giving it the ability to grind the drive gear against the selector fork. Once I put the case back together I noticed that the chain was not straight, so I pulled the main shaft out a little so that the chain would be straight, and walla, i noticed that there was a snap ring grove at just the right distance away to where the top of the rear retainers bearing would be. Now its of to the Dodge Dealer to order parts.....

Thank you too everyone for your help.....

Will

 

cool. good eye.

did you decide not to use the t-case saver gizmo ?

 

When installing the case saver, what all do you have to take apart? Does the housing slide back far enough or do you have to remove the drive shaft or something along those lines? Also, do you need to drain all the fluid or can you jack up the back of the truck to minimize spill? Just got mine in the mail and didn't want to start a new thread. Thanks and sorry for the semi-hijack.