It's possible the "new" t-case has a snap ring problem.
Since you pulled it from a truck with the same driveline, that is what I'd suspect.

 

How is this done, and how would I check the snap ring?? I know the output shaft is noticeably longer on the new one. This was what I had been hearing prior to finding this forum. Is it possible to just change out the front half of the casings with everything (bearings and such) still in it??

 

I'm thinking you can push/pull the output to see what's up with that.

Dlyter might be able to help with that since he's grenaded 4 t-cases.

 

You can just unbolt the tailshaft housing and look at the snap ring.. If the shaft isnt damaged from your first case you can just swap them out.. if the case came from the same kind of truck it should just bolt right in.. When you say the output shaft is to long what is making you think it is to long?

 

 

My bad. Swap the inputs. Just unbolt the 4 input bearing retainer bolts and it should come loose, allowing you to swap them out. $450 was way too much though.

 

I paid 500 for mine.. It was a rebuilt one though.

 

I paid $200 for my 241 from a junkyard and it works flawlessly, so I can't see $450 for a 1/2 ton case...

 

If I could find a tcase around here for 200 bucks I would have my truck on the road bragging about how awesome my Mega Viper is... Your lucky.. Sorry for the thread jack... Wombat just likes to hurt my feelings...

 

Okay, no problem. I am glad people are like me on here and give each other crap. As long as all is in good fun. So anyway, I pulled the input shaft from the old tcase, but couldn't get the new tcase to seperate. It was hanging up on the chain. I also had a helluva time getting the snap ring off to let it fall through. Any sugestions would be great. I have never worked on a tcase before, but do have quite a bit of mechanical ability.