I have a 1999 dodge ram 1500 4x4 v8 5 speed it has the 231 transfer case, the transfer case works fine in all gears in 2hi and 4 hi, it shifts into 4lo fine but when I go forward in any gear 1 ,2,3,4,5 it drives forward for a second then jumps and sits and grinds like crazy, but if i shift it into reverse it doesn't grind and it drives in reverse just fine and 4 lo works because i can feel the gearing reduction, put it in back in 1st or any other forward gear and it moves forward for a about a foot and makes a loud clank and then grinds terribly and it will just sit and grind, I changed the atf fluid in the transfer case and replaced both front axle u joints and it still persists. what is wrong with my transfer case, and is it toast or is it a simple fix? could it be a bad chain? I have been reading d.f. for 3 years but i finally have a problem bad enough that i needed to sign up finally to get help. lol there are a lot of smart people on here so i am hoping someone can chime in and help me out.

 

How did the fluid look? Was there any metal shavings in it? You might try removing the tail shaft and see if the snap ring is broken. http://www.drivetrain.com/parts_cata...ase_saver.html

 

the fluid looked ok, it wasn't bright red like new, but it didn't smell burnt either. there were some metal flakes in it, but they were very fine shavings in the old fluid but not a lot in there and no big shavings

 

Do the second part of zman's suggestion. If that snap ring is busted, you WANT to know.

 

If it were mine, I would disassemble the case paying special attention to the low range gear and synchronizers.

 

i cracked open the tailshaft housing, the snap ring is nowhere in site and the shaft has some play in it, could that also cause a rattling like noise i hear when i accelerate if i am by a cement devider when the sound echos back, and a howl / whining sound on deceleration in all gears but gone when coasting in neutral? or did i just destroy my case? i just realized 4 lo was bad a week ago because i never needed to use it since 4 hi i used and works great, but I drove it 25,000 miles this year so far with the sounds and never got worse, prev owner told me it was normal that some rams came with noisy 5 speed nv3500's? or is he just blowing smoke my way? Now I am debating getting the tcase saver hoping it fixes it, or purchasing a used t case, but no junkyards around here have one available for a 5 speed. it also has a 5.9 motor swapped into it, could that be too much stress on the case?

 

Well with that info, I would start by installing the T-case saver and see what it does for the forward low range problem. I wouldn't be shocked if that didn't cure the problem though.