So I've had an issue with my t-case for about 6 months now. 2wd works flawlessly but when in 4by it clacks and bangs HARD. It seems to be a random issue, not in sync. Bangs so hard the whole truck will shake. 4lo is just nasty. Almost seems like something is jumping or binding. I've tried my best to just not use 4x4 but now that winter is over with, I plan on taking a look tomorrow. So.. It's not my axle u-joints, it is not the actuator, it is not the driveshaft ujoints, not the double-Cardin joint, not the transfer case mounts. This, to me at least, leaves 2 things: ring and pinion or transfer case (I'm assuming chain). Driveshaft doesn't appear to jump on the pinion so I'm 90% sure it's transfer case problems. I'm splitting the case open tomorrow to have a look.

Hypothetically if it the chain, Anyone know where to find one? I've checked locally and online and nothing for a 231 D. I've found a lot of chains for a 231- J or C (jeep or chev) and was wondering, are the chains the same? Most of the 231- J chains are 1". Also, locally I found a 241 chain for $130 and was wondering if it will work? I've heard yes and I've also heard no. Ill spend the extra money for a 241 chain if it'll work.

This is a 231 chain I found, 1 1/8" chain with 31 links. Will it work?
http://m.ebay.com/itm/220465244395

Thanks guys.

 

yea it kinda sounds like the chain could have a ton of slop or the slider ring is not fully engaging,simular to a manual transmission,operated by a shift fork,this could be bent as well...

 

Don't think ill pull it apart today. It's a little chilly and it's raining. Tomorrow is supposed to be nice.

 

Anyone know if that chain in the link will work? Or a 241 chain? Any help is appreciated.

 

So tonight I split the tcase apart and I am left scratching my head.. Chain is good, no metal flakes or chunks, no broken sprocket teeth, everything turns good, no sounds, no marks on the case, nothing. Also pulled diff cover and ring and pinion is good. If I didn't know any better I would assume 4x4 works perfect. I have no idea.. Maybe internal in the planetary gear (last pic)? I should have got a video of the sound beforehand

 

I don`t know anything about transfer cases, but the oil residue im seeing on the gears and chain looks real bad. When was the last time you changed the transfer case oil ?.

 

inspect the slider gear and the keepers(square things) those are soposed to keep the slider ring in its position,also check the fork,make sure its not bent or cracked,also,do you have those little plastic holders on the very ends of the shift fork?? there should be no slop in all of this stuff...

 

That's my fault. My little brother was helping me out the other day and he put gear oil in it. 80-90. He didnt know any better. Truck hasn't moved since. It will be receiving ATF4 when rebuilt.

 

Go to quad 4x4. They have a crap Ton of information about parts and the like.

Looks like a full rebuild is in order.

I would highly consider looking around for a reasonably priced 241 before dropping cash on the 231.

 

I would love to, it's just finding one. I'm in a small town. Not much to pick from.


I do know that those plastic ends on the shift fork are done. There's supposed to be 3, I only found 2, and the 2 I have are finished. Makes me wonder where the 3rd is...