I went to pick up my son at work tonight, and had the truck in 4WD because of deep snow. I felt a vibration, but I wasn't sure if it was driveline or rough road. I didn't drive far before the front driveshaft came loose from the transfer case flange, and flailed a hole in the side of the transfer case. It is parked in a Food Lion parking lot, until things clear up enough to get it home.
I understand that the 94 has a 241 light duty, and if I have to buy a transfer case, I should spring for the 241 heavy duty. Will it bolt up without issue, and for a couple hundred more, what are the advantages to it? Any disadvantages to it? Blessings to you all, and Merry Christmas.

 

I don't think there is much point in getting the HD unit. It has a spot for a PTO, if you have any use for that, and because of that I think the HD unit might be a bit longer than the light duty unit, and may require your driveshaft to be shortened. (don't quote me on that without checking into it further.)

I don't recall the internal differences of the HD unit, but under normal use the LD unit stands up pretty well. Mine has been untouched for 13 years and a couple hundred thousand miles, as well as many I know of. Just my 2 cents.

I make sure to use loctite on those bolts as a rule, and be sure they are the same high-strength bolts that were used at the factory. Some guys will throw them in a bucket with crossmember bolts and everything else, during a transmission swap, and the stronger ones might end up elsewhere on reassembly.

 

I don't know what happened. The trans was rebuilt before I bought the truck. I did get pretty stuck on Wednesday, on the jobsite, in mud, but nothing that would tax the drivetrain. I have not had the front driveshaft off. So, I don't know what bolts were in there, and I don't know their condition, or if any were missing. I think that I lost them, and the shaft dropped, flailed around, and punched a hole in the t-case. Hopefully, the case is the only thing damaged. We have almost 25 inches of snow on the ground now, and I have no 4WD to get to where my Dodge is parked (13 miles away). So, it will have to wait a few days.

 

The CV joint is a problem..They dry out then fly a part.When I got my truck the front shaft was disconnected.Because the CV joint was a piled up.Lucky no T-case damage.I took the shaft to a shop and told me that they sold alot of the front shafts for the dodges.They told me the joints dry up and to use a needle zirk and grease the joint every 10K miles.I don't know if this is true,but thats what I was told.

 

2nd the CV joint came apart.

Hodge,
I don't think the 241 is made anymore, you may have better luck finding a 271 for replacement which should bolt right up but may require driveshaft modification, not sure though.

some good info:
http://quad4x4.com/Dodge%20Transfer%20Case%20Parts.htm


I got lucky and found a low mileage 241dhd as my tc has internal problems. I am also going to change out all driveline ujoints, cv joint and carrier bearing since they are all original. I am sure my cv joint caused the internal problem w/ my tc, will have to see when I get everything taken apart next week.

 

The chain is 1/4" wider in the HD case and the output shaft is MUCH larger. I just finished having one rebuilt to go into my truck. I may never have needed the extra strength, but it's nice to know it's there. I believe the case is the same length as the LD case.

 

I started to notice a slight vibration in my front end of my truck for several days, however I did not have time to look at it. While driving home from work the vibration became severe in short order and then a loud bang, I rolled noisly into a gas station and got out to have a look. Lots of fluid and shrapnel on the ground. The transfer case had exploded, after having the truck delivered home on a flat bed and having a look it appears the front drive shaft centre u joint was shot and this caused a severe out of balance situation which detonated the transfer case. I found a good used NP241 DLD for $600 and am installing it now. I will have to pick up a new front drive shaft.

 

WHat CV joint? My shaft has universal joints not constant velocity joints. Are you talking about the double cardan joint?

 

Thats the one...that big mess of u-joints at the T-case..

 

My 241 transfer case fragged at the front output shaft like everyone else's. Trying to be slick to get a PTO, I picked up a 241HD but the mechanic at the shop says the rear output is bigger than the original and the driveshaft won't slide in.

Does anyone know if you can just replace that rear yoke/spline piece at the U-joint? If the U-joints are the same size, that might work? Any/all thoughts welcome, the mechanic was a little annoyed when it didn't go back together so I need to come up with a solution

Thanks!

****************
97 5.9 mildly tweaked

 

Yes, you can just replace the yoke. You can buy them new from Dodge or find a 3500 series truck in a salvage yard. Be aware though, there are at least two different yokes that I am aware of, maybe as many as four. I'm putting a DHD into my 2500 and found a yoke on Ebay. I also bought the driveshaft out of a '95 (I think it was) 3500 that had the smaller DHD yoke. Measure your output shaft diameter and count the splines. I need to get rid of the smaller one I have as it won't fit my setup.

 

OK, so the U-joints on the 241DLD yoke and the 241DHD yoke are the same?

My old LD yoke size is 1-7/8" OD, 32 spline.

It looks like the one I need for the HD is 2-1/4" OD, 31 spline.

Does that sound right?

 

Actually, the big yoke is 2 3/16 and is indeed 31 spline, this is the one I needed and have. The smaller one I have, which also came out of a DHD, is the same as the DLD at 1 7/8, 32 spline. I'm going to do some checking on the truck it came out of, but it was a 3500 dually. I know for a fact that the transfer case in the truck had the PTO cover, which should make it a DHD by default. It has me wondering though. I believe all, at least MOST, of the Cummins trucks came with the 1410 series (I believe that is correct) u-joints.

 

I'm replacing my 241 DLD with a 241 DHD and the vehicle speed sensor is on the transfer case on the light duty but not on the heavy duty.... .. does anyone know what you need to do in that situation...
c an you add it to the T case on the HD...
the DHD is out of a 98 Ram1500 and going into a 95 Ram 2500 V10
any information would be a great help! !!

 

There's at least 3 versions of the DHD. The earliest ones had the same speedo drive (94-95?) because they used the same output as the DLD.

I think most guys find a way to use the ABS/speed sensor on the rear axle instead; like the later trucks used..