I was under the truck messing with the t case linkage to make sure it was tight. Then decided to take out the fill plug to look inside to see if anything was wrong, I didn't really see anything, but I did stick my finger in there and could easily move the chain so its pretty lose. Should it be really tight, or should I be able to easily move it with my finger?

I don't see how this could cause my 4wd problem though because the truck wont move at all.. Im new to transfer cases, but pretty mechanically inclined. Is a rebuild something I would be able to do myself? So far if I did I would assume I would need a new chain, rebuild kit, and transfer case saver, and what ever is causing my problem of it not engaging. Are these parts I can just pick up from the store or do they have to be specially ordered? I really appreciate all your help guys. I really want to get the 4wd to work so I can have some fun with the truck, plus I just bought a plow for this winter.

 

I would drop it, rip it apart, and see what you find.

How much could you move the chain?

Now, your truck doesn't move.... will it stay in place when you put it in park?

 

Well I could only fit my finger in the fill hole so far but it felt really loose, I didn't really have to push hard at all. I mean I know a loose chain could be part of it and could cause it to pop and stuff, but I don't believe it would cause the truck to not move at all.

And well I have a 5spd. the truck works fine in 2wd but in 4wd its like its in neutral, so yes it rolls and if I put it in gear and press the gas nothing happens at all. I could take a video showing what happens when I put it in 4wd tomorrow if that would help.

As for taking the transfer case apart, if I do there shouldn't be anything causing me not being able to put it back to the way it was because it is my only vehicle and I have school and work. That's why I don't want to get into it until I have a pretty good Idea of what is wrong.

 

Ok, sounds like you have it pretty much covered there. I think I would start lookin' real hard for a t-case out of a 94-97 2500. (just skip the diesel, and v-10 variants.) Then it would just be a direct swap, with minimal down time.

Taking apart a case you know is busted, pretty much assures you aren't going to be able to just put it back together again, and expect anything to work..... that is a big gamble on your only transportation.

Where ya at in Ohio? Last I checked, Dusseau's in Adrian had a 96 or 97 2500 with a v-8. That would have the case you need.

 

input spline shaft differs b/t being behind and auto and manual.

auto is 23 spline

manual is 29 spline

Further you need to know if its a DLD or DHD. Different mainshaft bearing size and I think also different size spine diameter size. That might be the hold up on the swap. Just be sure. It's likely everything will swap over and you just replace with donor parts.

Might be good to grab the shifter (if possible) and fab it in to yours.

 

I live in stow which is like Akron, Cleveland area. I have never heard of the place you are talking about.

I know mine is a 241dld, so if I find another 241dld even if its out of a 98 will it work? Like would the input shafts from mine (manual tranny) swap out with the one from the donor truck which would most likely be an auto? Then I should be good to go. Or maybe just get another tcase then rebuild it, then just swap it into the truck.

 

Did a little more investigating under the truck. I put all 4 wheels up in the air and put the tranny in nuetral and was playing with the transfer case linkage moving it in different spots then turning the rear drive shaft to see if I could get the front to spin.

Well it locked in and both driveshafts would spin then would disengage right after. I kept trying to repeat this but only could a few times each for like 3 seconds. Its like the linkgage is in the right spot, but whatever locks the gears together isn't working. Atleast I know nothing is awfully wrong because it worked for a second.

Im taking it to a transmission shop on monday just to get a second opinion about the transfercase problem, and also my clutch. when I press in the clutch it sounds like a dry bearing spinning.

 

Well I'm still trying to figure this out before I take out the t-case to really check. I installed a posi lok so front axle works good. and also just took off my tail shaft and installed a transfer case saver( snap ring was broken), but 4wd still doesn't work.

I can put it in 4lo and get the low gear, but the front driveshaft still does not spin. Now that ive pretty much eliminated everything else, does anyone have a good guess on why the front drive shaft wont lock in on the t-case? Just to give me a better idea of what to look for when I take it out.

T-case grinds when in 4hi but not in 4lo. When I installed the transfer case saver the shaft seemed tight and the output bearing looked good. ( Would advise everyone to install the transfer case saver, was $45.00 on ebay plus $5 for shipping and only took an hour to install, and that was using a wrench lol.)

 

I think it's an internal issue. Gives the impression that the chain and/or shift fork inside is bunk.

Find the Factory Service Manual and Parts Manual PDF downloads for free in the following section.

https://dodgeforum.com/forum/2nd-gen...d-how-tos-143/


You'll also find a thread about the tcase saver.

Remember, if you get a replacement tcase, know that one behind an auto will not bolt up to your with a manual. Different spline count and length of input shaft.

 

Follow this link and it will show you how to tear your t-case down.
http://www.jbconversions.com/pdf/16-1204.pdf


It is instructions for installing a SYE kit but the pictures will show you what it is going to look like inside.