I've searched and searched this forum and I've found some great info, but I don't have an answer yet.

I broke the rear case on my t-case, so I'm looking for a new one. I have the 5/2l with the NV3500 and NP231D. I found a 98 1500 automatic t-case and I can't seem to find the differences. Some threads on here suggest the input shaft on the manual trans t-case is shorter, but I can't confirm this as the threads I was looking at did not list the same model years that I see.

I have found links that list the input and output shaft splines as the same, but there is nothing that says for certain that they are a direct swap.

http://www.drivetrain.com/parts_cata...rts/dodge.html


My t-case tag says:
231 D(Model)
5210 5021AB(Assy)
4 8 99 1C(date)
272(ratio)

the one a guy has for sale says:
231 D(model)
5210 5022(Assy)
4 30 98 3(date)
272(ratio)

Can anyone tell me if this is a direct swap or if there is any subtle differences like input shaft differences, I can rob my broken case of it's input shaft to make that other case work.

 

There is a difference in shaft lengths. But I'll be damned if I can remember what,where and why. I do seem to recall some where I read, that it's not a big deal to actually cut the shaft shorter. But I don't remember if that applies to a manual.

 

I am not sure which has the longer input shaft, the auto or the manual one. Does anyone have that info?

 

just got off the phone with a trans guy, he said the input shafts are different lengths, they could be compatible if the plantery helix is the same, I could swap out my input shaft into the automatic t-case and have a good fit.

 

Good info, thanks for posting it.

 

So, I did find a good rebuilt NP231D from an automatic 1998 Ram 1500 for $300. So I got to work this morning in this:



It warmed up to a balmy 10f by 10:30 and I had the case out of the truck just before that by unbolting it and lowering it by using my legs and knees to support it under the truck.

So I was going to go use a cold garage across the street, something like a 400 yard wagon pull, one way, to use a cold garage, then my brain wanting warmth took over. So I setup the Clam 2000 with an old workbench top and my Mr. Buddy heater, mobile t-case shop,yeah!



All in all, this was an easy thing to do, about 15-20 minutes to get the input out of the bad one, then about an hour to get the good one apart and back together with the longer shaft. Of course there was some hemming hawing, lunchtime, cleanup, pickup time involved. Here are some pics.

You can see the longer shaft is for the Manual trans version.


The crack in the old case



The inputs:

 

nice price on the new tcase for 300. you did good.
also nice pics. we love pics.

those are some brutal working conditions. when you go to put it back in maybe you could drape a big tarp over one side and slide your heater under the truck for some warmth. be careful and don't stay out too long or get in a hurry and mess up.

 

I'm not worried about the tarp, I live on my in-laws ranch and doing automotive work out in the elements is normal, putting it in should only take me 20 minutes with help to stab it in place, and the weather will be warmer tomorrow, 30f.

 

Well ladies and gents, details to come, but this did not work....

SO, if you refer back to the images I posted above, you will notice something maybe, about the input shafts....On the right shaft, the "shoulder" is about 3/16-1/4" longer than the input shaft(from the manual) on the left. So after putting 30 miles(rough miles, peeling out, 4wd, crashing through the snow, getting stuck.....) this morning I planned on taking it for my morning commute, (40 miles each way) and it just made a grinding noise in reverse trying to back out the driveway, I could grab the t-case shifter and nudge it back 1/2" and it would grab and go, going forward seemed normal enough, but reverse would do that grinding....I parked it and went back to the pics to investigate, and I saw the difference, and it makes sense.....if that shaft moved forward, then it could lose contact with the output shaft. So, the case is pulled and tomorrow I'll tear down both cases and see what the difference is, either in the planet, or the front case. I'll be sure to get plenty of pics to soothe your eyehole's and to make sure anyone else trying to attempt this will know what they are up against.

 

I wish I could find the info, but that's where just cutting it come's into play.