Well... I am stuck in 4hi and I am wondering what's broken, here is what happened: I was having trouble going from 4hi to 2hi, the shifter would slide into 2hi, but the t-case would not disengage from 4hi. With some playing around it would eventually go. After towing anther truck using 4low, I was unable to get it to go into 2hi at all (even though the shifter was in the 2hi slot), the t-case stays in 4hi. To make matters worse, as I was trying to get it to pop out of 4hi, the t-case now grinds gears like mad when trying to shove the shifter into the 2hi position. I have to power the truck all the way off to get the stick into 2hi, which I HAVE to do because now if I put the stick in the 4hi position, it acts like the transmission is in neutral. I am assuming that my t-case is shot, but any ideas on what went wrong? Should I try to repair it or go junk-yard shopping for a new t-case?

The truck it is a '96 1500 with the 5.9L. I am pretty sure t-case is some flavor of 231.

 

well if you do go shopping look for the NP205 i hear they are really good.

sounds like the 4hi position is putting the transfer case into neutral rather than 4hi.

at best it sounds like you're going to have it serviced or dig into it yourself. you might try finding out if it is throwing any codes. that might very well be the problem.


or it's just worn out and done workin. it is 10 years old and all.

 

Yeah, I am going to dig into it this weekend, someone else told me it might be the shift fork. I am pretty sure it is repairable (might be wisfull thinking) because it runs fine in 4hi. If it is trashed, I was toying with the idea of replacing it with a stonger t-case. Is the np205 better, does it bolt up fairly well?

 

205 won't bolt up. The 205 was used in CTDs in the late 80s and early 90s...and in 3/4 ton and 1 tons before that.

Without adapters, the 231 is your only option. The 241 MIGHT be compatible, but I'm not sure the shaft would be splined correctly for your truck.

It does sound like you messed something up with all the gear grinding [>:] but it wouldn't hurt to check something before swapping the transfer case. The shift fork they're refering to is in the front axle...in the CAD housing. It might not be disengaging there. It's fairly easy to pop that off and see if there is a problem with the shift fork or collar. There is a cork gasket under the housing, but you can just silicone or RTV the cover back on.

And I'm not sure if you know this or not, but when going from 4hi to 4lo...or visaversa, the truck should be completely stopped. It can cause grinding if you're moving too much while trying to shift into or out of 4lo.

 

Thanks for the info on the different cases. And yes, I know that the truck should not be moving when I am going in and out of 4lo. The t-case only ground gears when I tried to go from 4hi to 2hi with the truck running.

 

hmm the owner's manual in my 01 said that you could do the 4hi to 2hi at any speed.... but not go over 25 in 4lo...

yeah who really believes those owner's manuals anyway...

does anyone know if there are any sensor that would throw a code in the transfer case? i imagine there is, but maybe not. could explain the no codes.