2nd Gen Non-Engine/Transmission 241dld transfer case problems

I rebuilt my transfer case a few months ago because when I put it in 4x all it would do is grind. When I tore it apart the range fork was shot and the middle pad on the mode fork was wasted. So i replaced them and also the slide lock and gear that locks the front drive shaft in. I put all this back together and it seemed to work fine until I hit the brakes decently and BANG grind grind. Now it was back to the same ****. So it is tore down RIGHT NOW AS I TYPE and all i could see wrong was the middle pad on the mode fork was missing one side, I thought i also might be a bent mode fork so I bought one of them and the original was bent about . 065 at the tips. I also checked the snap ring on the end of the output shaft and it seems fine. So does anyone know of anything else I should be looking at. I also looked at shifter linkage being off but nada. Fire away guru's!

 

Did you replace the thing the fork moves it could be worn in a way to let it walk out when not under power.

 

that will be the slid lock, yup I replaced it.

 

Is it full of fluid? I just recently had the same problem. The culprit was no fluid in the transfer case. Evidently, over time there is a way for the fluid to weep out and will eventually go dry. I had the same parts go bad as you, replaced them, filled with fluid, and have had no problems since.

 

fluid is a problem, it was full but I was using 85w 140 gear lube, according to chrysler it is supposed to be atf fluid. This go around I will use the recommended.

 

If I am not mistaken, the transfer case also has an oil pump. I would be curious if it was damaged by trying to pump the thicker 85w-140 gear lube. Also, I would inspect the bearings at the higher points in the case to see if they are toast in case the oil pump didn't move the gear oil.

 

well, did you figure out hat was the problem?