I have a NV 241dhd transfer case (TC) and tried to engage 4 low. The shift lever went into the 4 low position but the TC was actually in 4 hi and now 4 hi and 2 hi are where 4 low and neutral should be. I cannot pull the handle back to the correct positions. There are no damaging sounds coming from the TC however occasionally during high speed deceleration the shift handle will fall forward engaging 4 hi which easily goes back to the new 2 hi position. During a long highway decent the TC went into neutral by me pulling on it and I was able to reach the correct positions. When I got home I changed the fluid and tried to engage 4 low again and now I am back to where I started. There was no TC debris in the oil, it looked like it was well done though. Any ideas?

 

Sounds like the snap ring on the rear output shaft has broken.

Simple to fix, remove rear drive shaft, pop the rear output housing off and there will probably be 2 pieces of snap ring laying there.

The ring is about $8 from the dealer.

When it breaks, the output shaft tends to float around on it's own allowing the TC to engage 4wd when ever it seems to want to.

Would be the first thing I would check and you can leave the TC in the truck to do it. Shouldn't take more than an hour start to finish.

Jeff

 

Does anyone know the part number for the outer snapring for a 2002 241dhd, auto trans. Thanks!