No, drive it how you want. Shouldnt be a problem. Are you sure the front DS isnt engaged? I had a hub slightly locked once and made it barf on the freeway.
Just drove it 80 to work the case was cool to the touch
You guys feel I'm asking to much out of it?


The vent tube is ran up to the trans dipstick and its spray all over the firewall. Fluid is going up a 5 foot tube at a slope.


Bigger diameter vent tube and enlarge the hole in the case?
At some point the larger tube will not allow enough pressure for the fluid to climb that high and it will simply drip back down the tube into the case.
I'd go 3" for starters!
-G


To the best of my knowledge the 241 never had a pump rub issue, this was an issue with the 261/263 cases in the 2500-3500 trucks in the 2000+ model years. What size is the vent tube? It sounds odd your having this issue, and no your not being to hard on your transfer case. The 241,231 blah blah all share the same basic size and design of planetaries and the chains etc. don't change that much. There's something else at play here.
Too small a vent line that is too long will make the tcase push fluid up the breather and cause some issues. Also I've seen guys let it push fluid out until it stops and check what's left to find they lost 1/2 a pint and it's no big deal. I bet if you drain the case you have 1.5 or even 1.75 QTs in there and it's all good.

If you have any kind of loop or low spot in that breather line, that can also cause a problem like that. I had similar issues and making sure the lines were always pointing uphill seems to have solved it.
I think Steven Watsons advice to me once on the 205s (not the same as 241 I know) was that it only becomes a problem when the case stops leaking...
