anybody ever tear into the NP 241 DHD.i was having some strange noises either in the trans or tranfer case. sounded like gears slipping under a load.

figured i check the transfer first since it has first in line. uppon splitting the case i found a synchro insert and retaing spring in the bottom.

dont know what would of made it come loose. anyone ever have simular problems. fork pads looked fair but one is missing one side. i still dont know if this was the reason for the noise. should the syncro gears be able to slide out either side as the teeth have been boogered and stop short of the edge.

where is a good place to get a repair manual for this transfer case and transmission?

 

Get a Factory Service Manual for the truck, very good info in there, believe the CD version is 30 bucks from Genos Garage.

 

this is the syncro insert spring that was loose.the one on the other side lookes just like it so i assume nothing is broke off of it.

 

here is the side that has the messed up teeth and does not go flush to the edge.I dont know if it should.