2nd Gen Non-Engine/Transmission what's wrong with my rear end?

[Coalsmoke]

i'll check that on mine, I just had the pinion seal replaced last summer and I don't remember it starting the clunking until fall



now to find a 400 ft/lb torque wrench... ...

 

[-gtsm-]

check your transfer case now!

coalsmoke, Mine turned out to be the transfer case on it's way out! I'm sorry I didn't have time to post a follow up but i've been offshore since I did the repair. Even though I changed the fluid recently(a year or so ago) in my t-case, when I rechecked it it turned out to be real low ... apparently it was leaking,This caused excessive heat which melted the nylon pads on the shift forks which eventually allowed the t-case to try to engage 4-wheel drive while I was towing. My case was toast at that point so I ordered a new one from transfer case express and Installed it myself,4. 5 hrs. by myself start to finish (only dropped the new one on my chest twice). Cost me $1000 USD for the new case. check your fluid now before it's too late and if you see any melted plastic when you drop the fluid (dextronII atf) get a new t-case. BTW I tried the grease on the driveshaft thing,It's worth a try but check the t-case anyway. Good luck and lemme know if you need any more info,i'll be here for another day or two. Rich

 

[C. Harlan]

Mine is doing the exact same thing. I pulled the driveshaft out, checked the U joints, and all was good... When I did pull it off, I noticed a little bit of play in the driveline (Neutral, Parking brake set), but I am not sure if that is normal or not. . I have ~280k on the truck, so I am sure nothing is tight like a preacher's daughter anymore. .



I am confused, so I dont know what to think. . I do need to change out the diff fluid... I may do that Sunday. . Hopefully that will help out. I'm glad I am not the only one who is experiencing this same scenario...



-Chris-

 

[Devildog]

I had a Chevy that did the same thing, we went nuts trying to find cause. It turned that the drive shaft going into the transmission was dry and causing it to bind. We greased the splines, reassembled and it was good to go.

 

[Coalsmoke]

GTSM, sorry to hear it was your TC and thanks for the follow-up. I really don't think it would be my TC making this clunk. I just did a full-rebuild on it a few months ago and everything was and stil should be tight. If your case was trying to get into 4wd it should grind, not thunk like that. Did you notice grinding in the years past? Right now I'm suspecting either play where the DS goes into the TC, pinion nut not tight enough, or spring hangers loose. I'll go look into it today, see what I can find.

 

[nps]

Those jeans make it look fat :-laf :-laf

I thought about posting that since I first saw the thread topic, but decided I'd give him a break.

 

[HPetrat]

nps

Same here, butt then the devil made me do it :-laf



HP

 

[RMecum]

I thought about posting that since I first saw the thread topic, but decided I'd give him a break.

I was gonna say somthin' too but I was hoping for pictures! :-laf

 

[Makensmoke]

I too HAD the EXACT noise/clunk drove me crazy for over a year. I finally found it though after thousands of dollars in rear end parts, brake shoes (this is also something I haven't heard yet in this post... they'll stick and make that clunk as well) shocks, and "tech labor" as I gave up on it. The transfer case to transmission bolts were loose. It looks like you all have high miles on your rigs as I do, i'd check it out.

 

[Coalsmoke]

I too HAD the EXACT noise/clunk drove me crazy for over a year. I finally found it though after thousands of dollars in rear end parts, brake shoes (this is also something I haven't heard yet in this post... they'll stick and make that clunk as well) shocks, and "tech labor" as I gave up on it. The transfer case to transmission bolts were loose. It looks like you all have high miles on your rigs as I do, i'd check it out.

Thanks makensmoke, I had my TC off last summer, maybe I didn't get them tight enough, i'll check into it and see if it is those bolts. Do you remember if they were all loose? or just a couple?

 

[Coalsmoke]

not my TC bolts, they're all tight. I found a cracked rear brake shoe, is that maybe it?

 

[Makensmoke]

I'm thinking only one was normally tight, the others ranged from snug to spin off by hand. I can see it now when its back together (I had tc off too) where the tc was walking around by the marks on the case. Not much, but even a little is going to be noticeable.