2nd Gen Non-Engine/Transmission Noise when 4WD engaged

[PDDailey]

Howdy!! Like the forum lots am new to it as a member.



I have a 1999 4wd HD 2500 Laramie Excab with the Cummins, 5 sp manual, EDGE EZ, KN air filter, 4 inch exhaust.



My problem is I am hearing a "clunking noise" when 4wd is engaged in both 4hi and 4lo. Noise increases in frequency with ground speed. Have looked at visually inspected all ujoints, front drive lines, checked front wheel bearing play. Am stumped. Leaning towards problems in Transfer case.



Any and all help appreciated!!!!



PDDailey

 

[nps]

Welcome to the TDR. Sounds like your TC may be the source of the noise. There are 2 versions - the 241 and 241HD. The HD has a PTO port and a heavier chain inside.



The drive chain may be the source of your noise. Although some noise is normal - I assume this noise is clearly abnormal?



TC is pretty easy to R&R, and once opened, not alot of parts inside.

 

[J.Post]

Could also be a chiped tooth on the front ring and pinion. It happened to me w/ a Jeep I owned. I went four wheeling and when done I got back on the highway and started hearing this clicking noise that increased w/ speed. I also thought it may have been the transfer case as that is where the sound seemed to be coming from. Turned out to be my rear ring gear had a chipped tooth.

I say the front because you only hear it in 4WD. It's easy to check. Pop of the front cover and rotate the R & P and visually check for damage. Check the fluid as well when you remove the cover as any pieces should fall. Althoug the tooth from my ring gear was lodged in between the ring gear and the carrier. Fortunatly for me because it stopped any more damage from occuring.

 

[Crowhurst]

A frequent cause of problems is a fractured snap ring on the output shaft of the transfer box. This can be prevented by replacing it with a much stronger fitting, with details at http://www.drivetrain.com/gillies/Tcasesaver.html

If this is the problem, continued use will mean that the shaft moves backwards and forwards, causing noise and expensive damage. The snap ring is easily replaced without removing the transfer case. Drop the rear prop shaft after disconnecting its center bearing. Make chalk marks on the propshaft connections so that everything goes back in the same place, to avoid vibration problems. Remove the bolts holding the rear extension on the transfer box. Tap the extension with a soft mallet to break the joint. The snap ring, if complete, needs a strong pair of circlip pliers for removal. If yours has shattered, this will not be necessary. The new ring is fitted with an Allen (hexagon) wrench. Use silicon oil-proof joint sealant on the joint on re-assembly. If the extension oil seal is dripping, now is the time to replace it. The snap ring replacement is well worth doing to prevent problems, even if that's not your issue, IMHO.

Nick

 

[JVL IN PA]

I lost my transfer case @ 28,000 miles, sounded like popping when it first started, thought possible from exaust till it got worse and could hear metal. dealer had no explaination why it failed. obvious warranty.



04' 3500 SRW LB auto 4. 10's

 

[Cummins Thunder]

I think my snap ring is broken as I get that "pop... pop... pop" it mainly happens when I either get on the throttle or let off wjhile in 4wd.



CJ

 

[JVL IN PA]

After talking to a friend of mine that is a G. M. mechanic, he said the snap ring is the cause of most failures. If the ring gives you might as well order a new T. C.

 

[vssman]

If you think the snap ring is broken - stop driving the truck immediately or you'll experience significant transfer case damage. Don't ask how I know...

 

[TDoumit]

that clamp could be found at most bolt stores like our local vancouver bolt. if you know the size (which i dont) you might be able to save some time in getting it, probably $$ too.

 

[Hookemupman]

So when the snap ring fails in the transfer case is the noise only when in 4wheel drive mine has been pooping but only when in 4lo or 4hi. No problems when in 2wheel drive. Thanks Jason

 

[DZink24]

I hope this isn't your case, but a few months after I bought my 98 1500, (March/2002) I would hear a clunk-grinding noise when engaged and moving. Fortunately warranty covered it- there was a crack in the housing and the TC was dry