So Daniel (17 yr old son) saved his money and purchased a 94 dodge team 3/4 ton, cummins, standard trans 4 x 4.... Had it one day, 144.6 miles to be exact and had this happen. Front driveshaft snapped off, slammed into the t-case taking a chunk out and splitting it front to back. And folks this happened in a friends driveway, I know, I went over to help nurse it home, the blood trail of fluid suports his story. Anyone have a spare np-241 lying about that they would part with cheap

How am I supposed to get drews little pony out of the garage if I keep having to throw money at every other vehicle in the fleet?

This is a picture of the rear, look close, you can see the cracks...

Ouch!

Kapow! What caused that? I'd pull the case apart to see, hope it wasn't in the front axle...

Post up on CO4x4.org as I am sure you can find something there.

J.D.

So we found what we believed to be an identical case. Same tag and all, we were told it came from an identical truck and all. But nooooooo. The case on the left is the original, the one on the right is the replacement. Anyone know how to swap these shafts?

These are np241dld cases from 94 dodge cummins trucks.

I will even bring them to you with s for your time and teaching.

Pm me

Thanks

Ones from a manual trans and the other is from an auto. Here's some info I found. You might not be able to swap just the input shafts.

All gas V8 trucks with manual transmissions and all automatic trucks regardless of their engine have a female 23 spline input shaft. Whereas, all manual transmission trucks with a Cummins Diesel or Gas V10 engine will have a female 29 spline input shaft. Every NP241DLD transfer case will have two-piece tailshaft housing and have a 1-3/8" diameter 32 spline rear output shaft. The NP241DHD uses a 1-1/4" wide drive chain and does not have a provision to mount a Power Take Off (PTO). The 1997 and earlier models have a mechanical speedometer output that drives an external electronic sender.
During the early years of 241DLD production, two different cuts of planetary gear teeth were used. When swapping parts between cases, the original equipment Input Shaft, Planetary, and Annulus Ring must all have the same tooth profile. Other differences between various versions of the 1994-1997 NP241DLDinclude input bearing width, input shafts, and case castings. http://quad4x4.com/DodgeNP241DLD1994-1997parts.html

This reminds of a trip one of my buddys and I took up to Spring Creek once. About half way up the trail he splits the case of his 2000 F250 T-case. So we wraped it and sinched it up with a few ratchet straps to hold it together and get down off the mountain and back home. The point of the story is that you cant have enough straps and emergancy recovery gear.

Its also nice to have a Viperwolf1 in your tool bag.

So we spent Friday night in the garage pulling the guts out of one case and putting them into the other, the input shaft was wrong (I hope I have figured out the photo thing now and can post more than one piocture - we shall see). Then the wee hours between Friday night and Saturday morning were spent in the driveway installing said hybrid t-case. The result - absolute awesomeness!

So off to the pictures.

Mostly trying to figure out how to post pictures from photo bucket. if this works, it is the broken - yes as in split in two old case.

http://i1091.photobucket.com/albums/i38 ... 40_460.jpg

Sweet, so I got it figured out, and it is actually much easier to do this way.

I guess I can post some more pictures of the tear down and rebuilding of the NP241 t-case.

The broken U-joint that caused all this headache....


The case on the left is the original - if you look close you can see the crack all the way down the back side of the case, the front has a hole in it. The input shaft needs to be swapped into the new one on the right. That case is out of the same truck, except it has a 5.9l gas engine. Same trans and all. But the Cummins is just more stout...



Daniel removing some of the about 90 bolts, snap rings and locking rings that hold this thing together. Folks if you plan to attemt this, I have one piece of advice. Be organized. Remove parts and place them in order on your table or work bench. Work clean and work start to finish. I think if we had dissasembled one day and tried to return to it another day... no way would we have been able to get everything back to where it belongs

Ahhh - the guts... Shift forks and pads as well as all the gears look great. Unfortunatly all this has to come out to get to the planetary gear and input shaft... then that all has to come out of the other case, install the input shaft / planetary gear and the rest of the internals. Seriously folks, nothing inside the case shows any wear at all, if you need parts let me know. If you need a case - well best of luck.






All this on friday night so we could use Dan's truck to harvest our Christmas Tree on Saturday - and of course save the bacon of a Duramax that a friend drives... poor Chebby guys.