2nd Gen Non-Engine/Transmission Transfer Case Issues

[Todd G]

I have a 241 light duty and it makes bad sounds. I have replaced the notorious snap ring twice and noe the transfer case is making death sounds. When in 4wd it makes a loud banging like the chain is slipping on the sprockets. It does this only when moving forward. I can't get it do anthing abnormal in reverse. I have taken the case apart and replaced the chain with no effect. The insides show very little wear. I took the case to a friend that does transmission repair and he couldn't see anything that would make the nasty sounds.



Unless I can figure out what's happening, I'll have to either get a rebuild kit or a new transfer case. I'd rather not do either as I'm selling the truck (2004 followed me home).



Any ideas?

 

[Todd G]

Any ideas?

 

[nps]

You say noises only in 4wd going fwd. Could the CAD be partially engaged and causing the noise to radiate up the drivetrain? A u-joint maybe? I'm trying to look outside of the t-case as you say a second opinion has looked inside and says everything is good.



If the noise is definitely coming from the t-case, then suspect the shift forks may be worn causing partial engagement of the shift hub.

 

[Joe G.]

Remove the front drive shaft and see if that has any affect on the noise.

 

[Todd G]

I did check the CAD and it appears to be engaging completely. The front driveshaft and U-Joints look good also. It spins freely with no play when in 2wd. I did take the case apart again last night and the brass syncro ring has a little wear. It may be slipping in and out of 4wd.