Tell what you guys think. I have a 96 ram 1500 ext 5.2 with a 241d transfer case. I had it out in the snow for the first time, and I noticed that when i put into 4Hi while rolling, it will engage the front axle but the 4wd light wont come on until about 50 ft later, at same time the light comes on, it makes a hard clunk as if the axle binds for a moment and then it fine. Also when I try to disengage the 4wd, the lever goes back to the 2wd postion, but i have to turn the wheels all way one way to get it back into 2wd, otherwise it will just stay in 4wd if i go somewhat straight. The transfer case also has 210,000 miles on it, so i cant expect too much. All i did to it was change out the fluid with atf+4. Could this be a worn linkage bushing issue or alignment?

 

try just stopping and putting the trans in neutral when shifting into 4x4. ik the 98 and newer trucks have shift on the fly 4x4 but idk about the 94-97. i always stop and put it in neutral when shifting into 4x4

 

vaccum leak check all your hoses and connections if hoses are fine the its probably the plenum plate leaking

 

Yea im pretty sure its shift on the fly. Ill check the vac lines and readjust the linkage. I know its not the plenum leaking though. How quickly should a properly working 4wd system disengage itself?

 

http://www.dodgeram.org/tech/repair/..._engagment.htm

 

t-case wise its shift on the fly between 2 HI and 4 HI,

but - the CAD/Collar engagement encounters all kinds of problems related to the cad shifter, the collar, fork, bushings, axle alignment, and axle spines. sometimes you have to help it engage/disengage by stopping, backing up, pulling forward, cussing, etc.

 

yep the cad binds up alot especially if your running a spool up front like me. lol gonna do a cad delete on my d60

 

GOt so tired of the clunk in my 2004 one of the reasons i GOT RID. DODGE PEOPLE SAID COULDNT FIX. aAOTHER REASON BYE BYE 2004. dODGE dEALER NOW OUT OF BUSINESS, hmmm 94 NO PROBLEMS FROM 2HI TO 4 HI JUST FIRM POLL AND ITS IN PUSH AND ITS OUT SO SMOOTH I SPIN THE TIRES TO BE SURE. 89 SAME THING SMOOTH AS SILK.

 

I always shift into neutral, shift the transfer case, then let the light come up on the dash, then put it back in drive. Never have any clunking problems with that.