Busted transfer case---HELP!!!!
 

I just found out I have busted my transfer housing in my '95 Dodge Ram. Is there another direct bolt up that is beefier, does anyone have a stock replacement, or what is a decent price for a used one?

360 cui, auto

Trying to get before Slade this weekend, any help is very appreciated.

one from the cummins trucks should be a upgrade. I just do not know if it will bolt in or now.

I don't believe it will without some mods. I'll look into that for the future, Thanks.

Salvage yards around here are wanting $450. I found a fellow with tranny and transfer I may be able to deal with.

Can anyone tell me why my old input shaft is longer than the one I am planning to use? Will I have any issues?

The old one is the shiney one and tail of transmission. The dirtier and rusty one is the one I just picked up.

well the shorter one will not have as much engagement on your output on your tranny.

It looks like there is a lot of difference in the lenght in those 2 you might not even engage it at all.

you could swap the inputs on the transfer cases to make sure it works right but that would be a lot of work

I'm assuming they are both the same Dodge 23 spline (if I recall correctly)...

I would MUCH rather tear into a t-case and put the right input gear in than have less than normal engagement... Looks like there will be very little overlap... that sux.

Thanks. Both trannys look the same at the tail, I haven't measured to be sure though. The original was manufactured in '94, the new one was in '96.

How bad is it to change the output?

241 case is a bit stronger but i have wheeled the hell out of the 231's in all types of applications with no problems. make sure the driveshafts are not bottoming out into the case. they could be had for under 200 on some sites

I got tranny and transfer for $ 300. I thought was pretty fair. Anyone know anything about a 270's transfer, supposedly from a 2500 or so. Heavier chain, stronger built.

The front shaft has a slip yoke and it had plenty of clearance. A Dodge mechanic friend said to watch for binding on the front output.

i got one in a v-10 and one in a half ton... should have called me. sorry ,, mike

Thanks Mike, I should have known. I was rushing and trying to make the Slade trip this weekend. Not going to make it with my truck, hopefully may ride with somebody.

What is the one from the V-10? Is it said to be more stought than my stock 231D?

it will be a bit stronger. chain is wider.

Typically fractures in the case like you have are caused by one of the driveshafts binding or actually hitting the case on a rock or something. You can do a quick teardown of the case to inspect the internal parts, and if they look fine that is most likely the cause. An impact from a rock is pretty obvious. Once you get it back together I would get it really flexed out and check how much angle the driveshafts have left (if any). Keep in mind that the suspension, axles, and therefore driveshafts can move more (i.e. bind) when you are under power on a obstacle more than what you might see just parking the truck in a ditch.

New issue. The t case is in the shop, stopped today to check on it and now have another problem. Both are 231 D, the ratios are the same and the guy tells me the pressed gear in the front is a different pitch than the other so my front input shaft will not interchange. Says I need a different front housing or possibly a different shaft to make it work.

Anyone ever seen this issue before?

Also wondering if I can put lower gears in if I have to go that route.

I am no expert but it seems you are going through a lot of trouble & money for a 231 to work?

Yeah it sucks. Not sure of any other options that will bolt up to my transmission. If it's more than I want to pay I'll just have them put it back together and sell it. I'm open to any suggestions that may work.

I have a 231 out a 95 yj you can have if it will work! I have no use for anything off a jeep!! Me n Steve waited around Sat. b4 we went wheelin told him and bubba you was gonna try in make ride

I am pretty sure a dana 300 will pretty much bolt up in place of a 231 in a jeep. The front output will be on the wrong side but from what I understand they are fairly easy to flip

I appreciated man, still fighting this issue as you can see. I was hoping to be putting it in tomorrow but that's not going to happen. I don't know the difference in a Jeep t-case and mine. If you can, measure the input shaft for me and I'll check. I know they are different side drives but the shaft may work for me, depending on the spline. Too many variences in the same case, that's a bunch of crap.


(itbrokeagain)
I'll see what I can find out about the 300 as well, thanks dude.

I have a friend who has a case from a 1997 3/4 ton, 360, manual dodge ram for 250.00. if it does not work he will take it back.

I'll have to check on that. Got another connection to another stock replacement I'm looking at tomorrow now that I know the issues.

Been reading some of the doubler builds for the 231 on Pirate, anyone done this?