OT Dodge transfer case problem

R. Chris Jensen · Nov 18, 2009

I need some expert opinions. I was pulling a trailer the other day with my 98 Dodge 2500 when the transfer case slipped from 2 high into neutral. It has never done this before, but after the first time it will do it when going down even a slight hill. Has any body else experienced this problem. Is it a simple fix or do I need to rebuild my transfer case. Any ideas would be appreciated.

barn E · Nov 18, 2009

Does transfer case have synchronizer like manual trans?? All I know

steve n carol · Nov 18, 2009

I'd go to the DODGE forums

Jeff B. · Nov 18, 2009

Most likely cause is the shift forks. We sell hundreds of forks for transfer cases, and they are the most common problem of all. There is a range fork(hi-low range) and a mode fork (2wd & 4wd). Most likely cause is the range fork and the slider it goes in, although the mode fork could be bad,too. Since you have to split the case to change them, a bearing & seal kit is not a bad idea, especially if it has ,lots of miles on it.

railhead · Nov 19, 2009

Agree with going to the Dodge forums for better help. I have a 99 3500 4x4 dually and I tow with it often....never heard or even thought of that happening, 200K miles now. I did have to have tranny rebuilt at 120K (5th gear slipped off the shaft).

david - or · Nov 19, 2009

One very common problem on these trucks is that the snap ring securing the rear output shaft is brittle and breaks off inside the tailhousing of the transfer case. This allows the output shaft to slide fore-and-aft in the case, which makes a horrible grinding sound and eventually damages things. The noise is most pronounced as you go over bumps and the driveline flexes.

It is easily fixed -- disconnect the driveshaft at the rear end and pull it out of the transfer case, remove three bolts and pull the tailshaft off, inspect snap ring. The snap ring can be replaced with a less brittle one from a 727 Torqueflite transmission.

This may or may not have anything to do with your problem, but is quite common.

david - or · Nov 19, 2009

One very common problem on these trucks is that the snap ring securing the rear output shaft is brittle and breaks off inside the tailhousing of the transfer case. This allows the output shaft to slide fore-and-aft in the case, which makes a horrible grinding sound and eventually damages things. The noise is most pronounced as you go over bumps and the driveline flexes.

It is easily fixed -- disconnect the driveshaft at the rear end and pull it out of the transfer case, remove three bolts and pull the tailshaft off, inspect snap ring. The snap ring can be replaced with a less brittle one from a 727 Torqueflite transmission.

This may or may not have anything to do with your problem, but is quite common.

OT Dodge transfer case problem

R. Chris Jensen

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barn E

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steve n carol

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Jeff B.

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railhead

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david - or

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david - or

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