Yes its a 3/4 ton. I don't even have a grand into my rust bucket and it its not worth much more than that. So buying a rebuild it out of the question. If I'm understanding you right it has to be the 241hd only and a regular 241d will not work. Plus has to be 94-97 too. Maybe i'll pull it and bring it to a tranny guy and see if it something easy and go from there. I did call one and he said the problem could be something as simple as a fork (i think that's what he said) or it could be a whole rebuild.

 

Well, even if it is just the fork, (the pads on the fork tend to wear out, and fall off, then you get sloppy shifting, and other odd problems) he is still going to have to tear it completely down to deal with it. Might just as well address any other problems you find while he is in there. (and replacing the chain really wouldn't be a bad idea, if your truck is high mileage.....)

The 241DLD (light duty version of the case) is like an inch or so shorter.... so you may run into driveshaft length problems.

If you are mechanically handy, you could prolly do it yourself, if you have basic hand tools, and a place to work......

 

Do what my self? A rebuild? I never checked into it. I have done nothing like that before. I do have a small garage and tools. Maybe i should google it and see if it is something i could do.

 

If you are even slightly mechanically inclined, you could do it yourself. Have a friend to help, makes life easier. T-case is heavy when you are lying on your back, trying to bench-press it back into place.