[Enginebuilder]

I appreciate the advice to rebuild the unit that is in the truck already, as it would certainly eliminate any chances of getting one that is in worse shape, or worse, doesn't fit.

That said, the 'rebuild' kit doesn't replace *any* hard parts. Not even the fluid pump. It can best be described as a bearings and seals kit. I am not convinced that hard part replacement wouldn't be called for in my transfercase, as it is A: the original, B: was used as a plow truck for 70,000 miles, and C: the popping out of gear has been getting progressively worse, to the point where there is now a howling noise emanating from the TC area when the truck is running in neutral.

If I had to replace just one of the actual hard parts in this transfer case, such as the chain, it could easily justify the expense of buying a low mileage replacement, and then using the 'rebuild' kit on it, instead. (There are a number of NP241c's listed locally for anywhere from $150 to $500, with less than 80,000 miles on them.)

Engine: completely rebuilt
Transmission: completely rebuilt

The transfer case is next, followed by the front and rear axles.

The part number you referenced, BK241, shows as not being suitable for my truck; instead, BK241A is the recommended part. The difference between the two kits (both are for the NP241-c) is the size of the input bearing, with the latter being a 16mm bearing, and the former being a 24mm bearing. Any way to be sure of the bearing size prior to disassembly? I'd hate to get the transfer case apart, only to find that the bearing I needed wasn't included in the kit...

Another reason I'd like to get a second transfer case and rebuilt it, is that this truck is my only transportation, and being able to rebuild the second transfer case and swap it in would result in minimal down time.