One of the next steps in Old Red's overhaul is to either rebuild or replace the NP241D transfer case. I've got zilch experience with transfer cases so I'm leaning towards buying a rebuilt unit. Has anyone ever rebuilt one of these? Is it doable by a novice or should I go for the rebuilt unit with the warranty? What should I look for in rebuilt units?

 

Here is an exploded view of it a NP241.



They were used in mostly Dodge and Chevy trucks. They are pretty easy to rebuild as most "rebuild" kits are nothing more than just a chain, and few seals and maybe some bearings/thrust washers. The big thing to look for is metal shavings, chunks, etc. There will always be metal dust particles as that is from normal wear and tear. Its the larger pieces that you need to worry about/figure out where they came from.