okay well this is going to be part three of my transfer case rebuild this is an np241dhd
uh i'll put a link in the description of part one and two this today is a little bit bittersweet
i'm very happy to be getting this transfer case back together but unfortunately
my favorite blue shirt now has enough stains on it that
it's become a shop shirt so you know bit of a rough day but anyways time to get at her
all right well as you can tell my workbench organizational skills haven't improved there's
only one thing that's uh less funny than my jokes and that is uh the risk of getting some junk or
bits of metal anything like that inside the transfer case when i put it back together
so uh job number one is gonna be to uh well job number one is to get better jokes but
job number two is gonna be to get this bench clean okay well before we get started i just
have to say in all seriousness um this video is just for entertainment purposes only i've
never put one of these back together i took this apart and i've got a manual that i'm using but
i'm not a professional i don't really know what i'm doing i'm just trying my best so just keep
that in mind if you're gonna try one of these i would strongly recommend getting an atsg manual
step number one is going to be to replace this seal right here this is for the front output
okay well i got this uh bearing driven in here this one right here okay so now i've got the
bearing in i got that to seal in and now i'm just putting in the snap ring that holds this in place
okay now i'm gonna drive this uh bearing down inside there there we go that's in there
good everything seems to be spinning fine all right next up i gotta start uh assembling the
low range gear um this is the one you may remember from part two where i'm reusing this old bearing
okay well an entire can of brakes clean through this thing everything's spinning just lovely
i'm not seeing anything that makes me even a little bit nervous this bearing here that i
have installed in this case is not gonna work if you guys are ever doing a 241 dhd make sure you
get a kit that actually says dhd this bearing in here is far wider and the problem now is that i
need this bearing to fit on this shaft so that i can put a snap ring in right here and because
this one is so wide that ain't gonna happen so now i gotta knock this bearing out of here
i'll uh clean this one up as good as i can and um it feels fine you know um definitely not feeling
any grit or anything like that but there you go once again this kit just does not have what i need
okay well i got a nice bead of rtv around this this is the front bearing retainer
that is all installed got a new seal in there next up i'm going to replace this uh bushing and
o-ring in here that's where that new o-ring and bushing were so i've just gone ahead and put the
range sector in the other side so there's like a little detent ball up here
and uh that can kind of go like that and then sort of parks in there okay and next up i have to put
in the detent spring and ball uh right down in there that's what kind of makes it uh stick in a
certain gear just a little reminder as i mentioned in the first video when you go to put it together
and everything's labeled and uh in a bag you can just kind of clean it up and put it back in
it's worth its weight in gold searching around through a box of random crap is just not an option
when you're doing this kind of stuff okay well i got these new shift pads all right now next up
i'm going to be replacing the key and key and springs this is the parts that i bought these
were the broken pieces that i found in episode one i've got uh one spring inside which kind of holds
the keys and then a spring on the other side which holds the keys a drive sprocket installed
on the main shaft and next up i need to put the synchronizer stop ring on there so i've been
soaking everything or getting everything coated in atf here so now this one we'll go on there
so i've got the synchronizer hub on there there's these little lugs here that need to
fit in those slots so as you can see this can move in there okay and now this is a complete
unit got the snap ring in there everything's all lined up and good to go so coming right along
all right and it's now time to put the synchronizer sleeve on the synchronizer
hub this side as you can see is not beveled and then this side is beveled so the beveled
side goes against the stop ring which is that uh bronze gold colored piece
okay well i've got the synchronizer sleeve on the synchronizer hub okay and now i'm going
to change these shift pads on the mode fork i just realized this part here this needs to be
down inside here see if you can see in there there's those teeth
kind of right around here i'm pretty sure this is supposed to be living down inside there anyways uh
i'm gonna pull the pin on this for today you know i'm getting a little frustrated and this all just
needs to be done perfectly so i'll come back in tomorrow all right well it's a couple days
later took the day off yesterday i was getting a little frustrated and when you're doing this
kind of work there just really isn't any room for that you got to be kind of clear-headed and
go step by step um this is the range fork shift hub and this is the piece that i hadn't installed
and now i have to pull a bunch of stuff apart it actually is in the exploded diagram and they did
tell me to install it but there wasn't a picture of it and i just missed it and that's the thing
that can happen sometimes okay now one thing i'm just going to mention i took this transfer
case apart with these um pliers here these are channel locks this is a really common style
um it can switch to inner or outer they usually come with a bunch of attachments and
i got the thing apart with this but it was frustrating and you kind of have to fiddle with
it a bit um i went and got these ones today this is a set of gearwrench so as you can see they just
have like these grippy little paddle areas where they're a bit better for just sort of spreading
this apart and then you just kind of go like that whereas the other ones typically have
a hole that these pins would live in so if you're going to try rebuilding one of these do yourself a
favor and get a set of these okay so i've got the low range gear just gonna set that down
next i've got the uh shift hub um this piece here goes on there and
then there's a snap ring but you got to put it in through here first so i'll drop that in
make sure that's sitting nice next you go thrust washer
and then this unit
then another thrust washer
then i believe this is called a retaining ring
and then i've got the snap ring to go in and hold it all together
okay push around there make sure it's firmly seated in the groove now flip this over
now we need to put this ring on the hub
put a little atf on stuff so everything goes together nice
okay and then i've got my snap ring here okay looks good okay now i've got that unit dropped
back in here so i'm gonna put the snap ring on there and i can kind of continue on okay and now
i've got some rtv on here i've got uh atf on that seal and i'll just gently sort of get it on there
all right well that wasn't too bad now i'm back to the point where i was uh whining and complaining
about having to take it all apart all right so this actually i have to come back apart again
oh man i'm uh really putting on a clinic here okay so this needs to talk to this so
this is sitting in a slot you probably can't see it down there
but i'm pretty sure this is where it ought to be so all right so that one's on there
make sure this is properly seated okay and now i can put the main shaft assembly in here
okay this is not quite setting into the case
i'm just gonna go slow and there it goes okay now next up i'm going to uh
replace the pilot bearing so this is what it lives on this is the front output shaft
make sure it's going in straight okay now time to put in the front output shaft and the chain
okay well i just uh put some atf on the bearing of this front output shaft here i just removed the
seal out of this pump here
okay seal is installed put a little atf around it just to keep it happy okay now i've got the
mode spring which goes on the shift rail so that is there everything looks good
okay i've got the uh oil pump all ready to go got the screen cleaned out the pickup tube is in there
new o-ring everything's lubricated so i can set this off to the side
okay now i'm going to drop the magnet down inside the front case
okay now i'm just getting ready to put the rear case half on there's a few things i'm gonna have
to be careful for this spring is just kind of sitting here so that has to index with a certain
spot there um i need to get the front output shaft in its bearing and then i need to get the oil pump
splined properly onto this so first things first i'm just going to dump a little oil on this chain
manual did say to coat all the components with atf so i've been trying to do that
okay well um i'm starting to think that the oil pump actually goes on the outside of the
case i had it on the inside to begin with so that would make a little more sense there is a
notch right down in here that the pickup tube lives in so now i'm going to try and lower it
on this way just something felt not quite right and if it doesn't feel right just figure out why
okay there we go so now that i know how it goes together i'm going to pull it apart put
a bead of rtv on and away we go okay so now i'm going to just go ahead and put the bolts through
the only thing the manual mentioned is the ones with washers need to go uh in the ones that have
the dowel pins all right now we're really coming along i got the case halves together everything's
tightened up i just knocked this bearing out of this i think it's called the rear retainer
or something like that so now i am just going to set the new one in there and then drive it home
okay that appears to be seated everything's spinning fine
okay now i'm going to drop this on here
i just put on the speedometer snap ring and gear there's two snap rings and a gear i was getting
right down to it and i found this little piece of uh a snap ring um i've been noticing it in
the parts box lately i wasn't 100% sure where that came from but i figured i would eventually
figure it out and i'm kind of starting to remember now it's been a couple months but i think when i
uh pulled off this cover um that something dropped on the bench anyways i called we have
a really good local transmission part supply place it's called tcs anyways i called them
expecting to just get a new snap ring and they actually told me it's a common problem
and they told me about this uh bunch of stuff which actually replaces it if you remember from
part one when i got in there and found uh these broken snap rings uh which i've also replaced
now i'm pretty sure that happening and this snap ring here breaking we're probably related
but basically you've got these two rings and this has a groove in it so these would sit
um on the shaft where the original snap ring went in that's where that groove would go so those are
going to sit like that and then you've got this really thick ring that goes over top of that
so that'll be sitting like that and then you've got like a conventional style of snap ring
goes over okay and there is the finished product installed snap ring is uh good and
tight everywhere this seems like a far beefier unit all right well as you can see i've got this
extension housing on got the uh inspection cover on um it's pretty messy with uh rtv but i will go
ahead and pick that off anyways uh the biggest surprise is that uh typically you would expect
to see this kind of boot right here um this one doesn't fit so it's kind of hard to show but there
are two sealing surfaces there's the one on the outside and there's another one like that inside
considering how accessible this one is i'm gonna go ahead and just give it a try like this you know
worst case scenario if i gotta pull off these four bolts if it starts leaking
um and then just pop the drive shaft i can obviously get a new one in there so
i'm not too concerned about that um you know i'll give this one a try for now just see how it works
anyways uh the last thing i have to do is put in the speed sensor so i'm going to do that now