Engine/Transmission (1994 - 1998) Tranfer case noise

[Rosshatfield]

I have a 95 2500 4x4 with an automatic. It makes a very annoying sound whenever its under a load. If I am climbing a hill or just have my foot in it I can hear a rattle coming from the Tranfer Case. I goes away when its in 4 wheel drive or when I put pressure on the 4 wheel drive shifter. I have heard that these tranfer cases get some slop in the chain and thats were the noise comes from. Is this true and is there anything you can do about the noise other than putting a new transfer case in or turning up the radio?

 

[vssman]

I blew up my T-case a couple of months ago. It would make a horrible noise in 2wd and go away in 4wd. Turns out that a snap ring broke allowing a gear to "float around". It made a mess of the T-Case. Apparently there is an update kit with a stronger snap ring. Get it looked at ASAP because you can wipe out the entire unit - I learned... .

 

[SBrandon]

if it is the snap-ring, it is fairly easy to change. The snapring is located behind the tailshaft cover which you can pull down your drivesaft and remove the four bolts holding the housing on and it is right there. Definitly get that looked at. As far as chain slap in 2wd no way, the only time the chain is moving is when it is in 4wd.

 

[vssman]

I only drove mine to work for 1 day making the 'noise' = approx 40 miles. Last 15 miles were in 4WD just to get it to the shop. Again, T-case was trashed. Rebuilder told me that if I had stopped and had it towed when it started to make noise it would have been an easier (and cheaper) fix.

 

[Jff24Gordn]

Drop the front drveshaft and put it in 4x4. This will get you around till you get it fixed. I did this last summer and drove it over 600 mi till I got the parts. I used the fix from http://www.drivetrain.com/gillies/Tcasesaver.html which is a clamp that goes on the shaft that wont break again.

 

[Dave Remillard]

Gillies snap ring replacement is a terrific solution. I also blew up my transfer case a year or so back and now have the gillies clamp. I'm not going to worry anymore about that breeaking as something else would give before it would. IMHO